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NUMERICAL PREDICTION OF THE SPRINGBACK
PHENOMENON IN SHEET METAL FORMING

(L-BENDING )
By
AHMED ZAHID HUSSAIN(02086063L)
MD.WASEEM AHMED(02086028)
MUHAMMAD ANWAR(02086067)
Under the Guidance of
DR. B.CHENNAKESEVA RAO
PRINCIPAL AND PROFESSOR IN MECH ENGG DEPT.
Submitted to
Department of Mechanical Engineering
CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY
(Affiliated to Osmania University)
GANDIPET, HYDERABAD- 500 075
october, 2010
ABSTRACT
The general outline of the project is as follows.
1. In the present study, the deformation mechanics of the spring back phenomenon in the L-
bending of sheet-metal was examined and a new method that could efficiently reduce spring back
in the L-bending of sheet metal was proposed.
2. A reverse bend approach that can efficiently reduce spring back was proposed to reduce the
spring back in the L-bending process.
3. An experimental and numerical study to reach a better understanding of numerical prediction

of the spring back phenomenon in sheet metal forming and various physical and numerical
parameters involved.
4. Finite element analysis software is considered to prepare an adequate numerical model. An

experimental and numerical study was carried out to reach a better understanding of the
sensitivity of spring back to various physical and numerical parameters.
5. The finite element software (ANSYS/LS-DYNA 5.71) is used for calculating the spring back.
Introduction
what is spring back?

Spring back can be defined as an elastically-driven change of
shape of a deformed product which takes place during
removal of external loads.
The spring back in sheet metal forming can be described as

the change of sheet metal shape compared with the shape of
the tools after forming process
Why spring back is improtant to consider
in sheet metal forming?
1. Sheet metals with high strength-to-modulus ratio such as high

strength steels and aluminum alloys are particularly prone to
spring back, and these materials are becoming more
important in automotive industry to reduce the car weight and
increase fuel efficiency.
2. Spring back makes difficult in die design because the final

part shape does not conform to the tool geometry.
Reverse Bend Approach:
The practical approach commonly adopted in
the sheet-metal industry to reduce the spring
back is to compensate the spring back by
bending the sheet inward.
However, it is not possible to do this if the L-bending

draft angle for the punch is negative.
In the present study, a reverse bend

approach was proposed to reduce the spring
back in the L-bending of sheet-metal. In the
reverse bend approach, the sheet metal is
first bent locally to an opposite direction of
the desired bend into a hemispherical bead
shape and then is bent at the bead location
by the punch to the desired shape, as shown reverse bending
in Fig.
Predicted Results and Discussions:
 The stress distributions in the bent

sheet obtained from the finite element
simulations were transformed into the
axial direction accordingly, and the
stress distribution mentioned is
associated with axial direction.
Based on the stress distribution

patterns,the bent sheet is classified
into three zones:

1. flat zone under the blank holder,
2. bending zone at the die corner and
3. unbending zone at side wall
Predicted Results and Discussions:
 Stress zones are marked by I, II, and III,
respectively in Fig., and the stress distributions in
zone I and zone III are displayed in Fig. as well.
Fig. displays the stress distribution in zone II.
Since the stress distribution in the flat zone is
nearly uniform compression, it is obvious that the
spring back is independent of the flat zone, i.e.,
zone I, and is mainly attributed to the stress
distributions in zone II and zone III.
Stress distribution in zone II

 The main effect of adding a reverse bend to the
V-bending process is to change the deformation
mechanics in the stress distributions in both zone
II and zone III. The stress distribution in zone III
is much improved when the reverse bend
approach is applied to the L-bending process
Undesirable effects of reverse
bend:
Although the reverse
bend approach can
reduce springback
efficiently, it may cause
uneven surface at the
die corner area. Hence,
the use of reverse bend
approach must be
cautious if high surface
quality is required. The unsmooth area after
L-bending with reverse bend.
Conclusions:
 The deformation mechanics of spring back phenomenon in the L-bending of sheet-metals
was investigated by the finite element analysis.

 The axial stress distribution in the bent sheet was classified into three zones: the flat zone
under the blank-holder (zone I), bending zone around the die corner (zone II), unbending
zone next to the bending zone (zone III). The stress distribution in zone I is quite uniform
and hence has little influence on the spring back. the stress distribution in zone II results
in a positive spring back, whereas the stress distribution in zone III produces a negative
spring back.

 The finite element analysis reveals that the stress distribution pattern varies with the use of
the reverse bend approach, resulting in a significant reduction of spring back

 However, the reverse bend may cause uneven surface at the die corner area, Hence, the
use of reverse bend approach must be cautious if high surface quality is required.

 The finite element analysis performed in the present study can validated by experiments as
well. The good agreement is expected between the finite element simulation and the
experimental data confirm the efficiency in using the finite element analysis in the L-
bending process of sheet-metals.
Thank you

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NUMERICAL PREDICTION OF THE SPRINGBACK

PHENOMENON IN SHEET METAL FORMING

Under the Guidance of

DR. B.CHENNAKESEVA RAO

PRINCIPAL AND PROFESSOR IN MECH ENGG DEPT.

3. An experimental and numerical study to reach a better understanding of numerical prediction

4. Finite element analysis software is considered to prepare an adequate numerical model. An

what is spring back?

The spring back in sheet metal forming can be described as

1. Sheet metals with high strength-to-modulus ratio such as high

2. Spring back makes difficult in die design because the final

However, it is not possible to do this if the L-bending

In the present study, a reverse bend

 The stress distributions in the bent

Based on the stress distribution

Stress distribution in zone II

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