Abstract
One of the most significant problems in bending sheet metals is the springback behavior caused by the elastic stress formed after the bending process. In this study, the effects of forming pressure, die angle and holding time on the springback behavior were experimentally investigated for V-bending using the flexforming process. Furthermore, springback behavior was predicted using a fuzzy logic system based on unexecuted break-test parameters. The study was carried out using a thin rubber membrane instead of the thick ones normally used in flexforming processes. During the flexforming process, it was observed that springback were 60.57% and 41.92% less than those formed by a conventional die for AL1050-0 and AL5754-0 sheet metal materials, respectively. It was determined that an increase of 15 degree in the die angle increased springback values on average by 0.12 degree and 0.23 degree for AL1050-0 and AL5754-0, respectively. It was also found that an increase of 10 seconds in the holding time decreased springback values on average by 0.14 degree and 0.19 degree for AL1050-0 and AL5754-0, respectively. It was determined that there were no forming defects on the surfaces of the parts bent through the flexforming process.
Highlights
The flexforming process is a sheet metal-forming method in which a sheet material is formed on a single fixed die by fluid pressure
This study aims to experimentally investigate the formability of aluminum sheet metal materials using a 4 mm-thick rubber membrane and only the female part of the die through V-bending using the flexforming process
The results obtained from the experimental work was evaluated and interpreted by considering the effects of die angle, holding time, bending pressure and the mechanical properties of materials with springback
Summary
The flexforming process is a sheet metal-forming method in which a sheet material is formed on a single fixed die by fluid pressure. This method is extensively used to form a large variety of sheet metal parts and parts manufactured in low volumes. Accurate estimation of springback is a very important step that needs to be taken into account during the design stage of the die. This is because, for the compensation of springback after die production, the correction of the geometry or determination of the ideal bending parameters by trial-and-error is time-consuming and costly
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