Finite element simulation of twist forming process to study twist springback pattern

M N Nashrudin,A B Abdullah,S.A Che Ghani,W.A Wan Hamzah,A Alias

doi:10.1051/matecconf/20179001026

Abstract

Springback is one of the most common defects found in the metal forming of automotive parts. There are three conditions which can be considered as springback i.e. flange angle change, sidewall curl and twist springback and among them, twist springback is the most complicated problem. This study will focuses on the development of finite element simulation model of the twist forming process. The main aim of this project is to investigate the parameters that may affect the twist springback. Few parameters including twist angle, hardening constant and thickness are explored using finite element (FE) software ANSYS Workbench (16.0). The rectangular mild strips are used to form the twist forming. The standard material properties and stress-strain curve of mild steel had been used to get the springback prediction. The results of springback were measured by the difference of the bending angles before and after unloading process. The results were then be validated with the research made of Dwivedi et al., (2002). The results show that the springback angle reduces as the thickness of strips are increased and also as the angle of twist increases.

Highlights

In automotive industries, metal forming is the main process used in manufacturing process
The parameters that have been used were different twist angle, the different thickness of strips and the strain hardening index, n of 1/3 for mild steel with material properties stated on Table 1
The results show the percentage difference between the both results are quite large but the curve patterns are similar

Summary

Introduction

Metal forming is the main process used in manufacturing process. The raw material is deformed plastically to obtain required shape and size. Examples of the process are forging, rolling, extrusion, sheet metal forming and hydro forming. The primary shape of a car is created by plastically deforming the material. The dimension must be precise to assemble another parts into it. Quality and productivity are vital issues as it is related to the cost of manufacturing. Every forming process, there are defects can be occurred and one of it is springback.

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