Analysis of fracture in sheet bending and roll forming

Abstract

The bending limit or minimum bending radius of sheet metal is conventionally measured in a wiping (swing arm) or in a vee bend test and reported as the minimum radius of the tool over which the sheet can be bent without fracture. Frequently the material kinks while bending so that the actual inner bend radius of the sheet metal is smaller than the tool radius giving rise to inaccuracy in these methods. It has been shown in the previous studies that conventional bend test methods may under-estimate formability in bending dominated processes such as roll forming. A new test procedure is proposed here to improve understanding and measurement of fracture in bending and roll forming. In this study, conventional wiping test and vee bend test have been performed on martensitic steel to determine the minimum bend radius. In addition, the vee bend test is performed in an Erichsen sheet metal tester equipped with the GOM Aramis system to enable strain measurement on the outer surface during bending. The strain measurement before the onset of fracture is then used to determine the minimum bend radius. To compare this result with a technological process, a vee channel is roll formed and in-situ strain measurement carried out with the Vialux Autogrid system. The strain distribution at fracture in the roll forming process is compared with that predicted by the conventional bending tests and by the improved process. It is shown that for this forming operation and material, the improved procedure gives a more accurate prediction of fracture.