Experimental analysis of air bending in multi layer sheet metal forming

Abstract

This study focuses on the experimental investigation of V-bending newlineprocesses involving multilayer sheets of aluminum and copper, specifically newlinethe Al/Cu/Al and Cu/Al/Cu configurations. V-bending is a widely used sheet newlinemetal forming process, and the springback effect-where the metal sheet tends newlineto return to its original shape after deformation-poses a significant challenge. newlineThe goal of this research is to better understand how key bending parameters newlineaffect springback, including punch travel, die opening, bend force, and sheet newlinewidth. By examining these variables in detail and conducting numerous newlineexperimental trials, the study aims to provide insights that can optimize the newlinebending process and reduce undesirable springback effects. newlineIn the initial phase of the study, a comprehensive analysis was carried newlineout to identify how different parameters influence springback. The newlineexperimental results reveal several critical findings. First, increasing the die newlineopening results in a corresponding increase in springback, making die newlineopening the most significant factor in the process. This is because a larger die newlineopening allows more room for the sheet to relax after deformation, leading to newlinemore springback. Furthermore, an increase in sheet width and punch travel newlinealso leads to greater springback. The relationship between springback and newlinesheet width was found to be particularly pronounced: as the width of the sheet newlineincreased, the average springback for both Cu/Al/Cu and Al/Cu/Al sheets newlineincreased. Conversely, springback decreased as the thickness of the sheet newlineincreased. This inverse relationship between sheet thickness and springback is newlineattributable to the fact that thicker sheets exhibit greater stiffness, which newlinereduces their tendency to revert to their original shape. newline newline