ME-7020

Finite Element Methods 2

Final Project
Simulation of Spring back Effect











2

Introduction
In sheet metal working, sheets are deformed to cylindrical and helical shapes by plastic bending with the
help of a punch and die set. When such bending is properly done, the inside contour of the section
matches the surface contour of the die during the forming operation. However, after the release of the
applied loads, the contour assumes a different shape than that of the die because of the release of elastic
stresses in the metal. This elastic distortion is commonly called springback. Springback complicates tool
design in that the die must be designed to compensate for it. Consequently, it is desirable to have a
method of quantitatively predicting the magnitude of springback as a function of the properties of the
material and geometry involved in the forming operation.
The spring back is a complex phenomenon and it depends on process parameters and material
parameters. A lot of research has been done to investigate the parameters affecting spring back and to
reduce spring back. Over bending is the simplest way of combating spring back problem, especially in V-
die air bends. The work piece is bent through a greater angle than required and the work piece springs
back to the required angle.
Spring back for low carbon and soft non ferrous material is from 0 to 20. For 0.40 to 0.50 carbon steel
and half hard materials spring back may vary from 3 to 50. Spring back may be as high as 10 to 150 in the
harder materials. These figures are only used as approximations because of other variables that influence
spring back. The practical way to determine the necessary amount of over bend is trial and error method.
In recent years the Finite Element Analysis is considered as an effective tool for the prediction of the
spring back.

Principle of spring back
The elastic stresses remaining in the bend area after bending pressure is released will cause a slight
decrease in the bend angle. Metal movement in this type is known as spring back, as shown in figure 1.
The magnitude of the movement will vary according to the material type, thickness and hardness. A
larger bend radius will also cause grater spring back. [3] Commercially available finite element analysis
(FEA) software is used to analyze bending and spring back of different aluminum materials of different
thickness. For forming process the material is stressed beyond elastic limit so that the permanent
deformation takes place. The material state becomes the plastic deformation zone; hence the sheet
metal can be formed.




3

Model:

Material Properties : Ref - Abaqus manual - Example problem 1.5.1
Young's Modulus : 2.06E6 Poison's Ratio: 0.3
Plastic cards - Imported from abaqus example problem 1.5.1
Blank dimensions : 350mm x 5 mm
Thickness cases : 1 mm , 1.5mm , 2 mm
Co-efficient of Friction cases : 0.05 ,0.1 5 ,0.2

FEM model in Hypermesh
Only half model is simulated as model is symmetric about x axis

Iso parametric view Z-X View

The die punch and blank holder are been modeled using Rigid body elements R3D4
The blank is modeled as a single layer row of S4R elements
Hour glass control card is being used to prevent hourglass modes
Boundary Conditions used :
Die
Holder
Punch
Blank


4

Punch velocity =12.5 m/s , but during the forming step displacement control is used accordingly
Blank is symmetric about x-axis
All the 6 degrees of motion of die is constrained.
The Punch and die is are constrained in x , y axis and rotations about y axis and z axis is
constrained
A force of about 175 N is applied on the holder

Analysis methodology

The forming process is first simulated using Abaqus explicit mode.



.
Since the fundamental frequency of the blank will be low , explicit would take extremely long
time to complete the analysis. Modal frequency analysis of deformed blank was around 32.5 hz
as shown





5

The deformed mesh after the forming process is further imported into abaqus implicit mode
and spring back analysis is simulated



The initial conditions for the model in implicit is applied by defining " predefined fields " option
in Abaqus GUI. Hence all the loading conditions and material conditions , after forming process
are applied on the deformed mesh in the implicit mode

The spring back analysis is performed and the spring back angle is found out using the query
results .







Nodes selected for
finding angle


6

Effect of friction on spring back angle :
The effect of friction on spring back angle is studied by varying the friction values . The blank thickness
considered is 1.5 mm thick and the velocity of punch is 12.5 m/s.
The values of friction used are 0.5 , 0.1 ,0.15 0.2
.COF = 0.5 COF=0.1

Spring back angle = 0.279 Spring back angle = 1.049
COF=0.15 COF=0.2

Spring back angle = 2.319 Spring back angle =3.15




7


Effect of thickness on spring back angle
The thickness values of blank for which spring back angle are calculated : 1 mm , 1.5 mm , 2mm
Thickness =1 mm Thickness =1.5mm

Spring back angle= 2.4 Degrees Spring back angle= 1.046 Degrees
Thickness =2 mm

Spring back angle= 0.27 Degrees



8

Graph of thickness vs spring back angle


Effect of clearance width between punch and die on spring back angle
A model with blank thickness of 2 mm was considered for the study. As seen below the clearance
between the die and punch is 2.3 mm and 3.5 mm

Subsequent spring back analysis of the model



Clearance = 2.3 mm
Spring back angle : 0.25 Degrees
Clearance = 3.5 mm
Spring back angle : 0.47 Degrees


9

Conclusion:
The following conclusions can be drawn from the analysis performed by changing various parameters like
thickness of blank , coefficient of friction and the clearance gap between die and punch
The spring back angle increases with the increase in coefficient of friction values
The spring back angle increases with the increase in the clearance between the die and the
punch
The spring back angle decreases with increase in thickness

References
Spring back in Sheet Metal Bending-A ReviewGawade Sharad1, Dr. V. M. Nandedkar21 (Research
scholar SGGS, SRTMU, Nanded-India.)
Abaqus 6.10 manual
On the relation of equivalent plastic strain and springback in sheet draw
bending M. Kadkhodayan, I. Zafarparandeh
Colgan, M., and Monaghan, J., "Deep Drawing Process: Analysis and Experiment," Journal of
Materials Processing Technology, 132, 35-41, 2003.
Ibrahim Demirci, H., Yaar, M., Demiray, K., "The Theoretical and Experimental Investigation
of Blank Holder Forces Plate Effect in Deep Drawing Process of AL 1050 Material," Journal
ofMaterials & Design, 29(2), 526-532, 2008
G.Y. Li, M.J. Tan, K.M. Liew Springback analysis for sheet forming processes by explicit finite
element method in conjunction with the orthogonal regression analysis, Int. Journ. Of Solids and
Structures, 36, 1999