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Lecture 26: Plane Strain Bending of Strips: Dept. of Mechanical Engg., NIT Calicut

1) This document discusses the plane strain bending of metal strips where the thickness is much smaller than the other dimensions. It considers the analysis of bending strips to achieve a permanent curvature. 2) The analysis objectives are to determine the maximum bending force, estimate the elastic springback after bending, and determine the minimum punch radius to avoid fracture. 3) It presents equations to calculate the maximum strain, minimum punch radius, distribution of stresses during bending, maximum bending load, and amount of over-bending required to account for elastic springback after forming.

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30 views

Lecture 26: Plane Strain Bending of Strips: Dept. of Mechanical Engg., NIT Calicut

1) This document discusses the plane strain bending of metal strips where the thickness is much smaller than the other dimensions. It considers the analysis of bending strips to achieve a permanent curvature. 2) The analysis objectives are to determine the maximum bending force, estimate the elastic springback after bending, and determine the minimum punch radius to avoid fracture. 3) It presents equations to calculate the maximum strain, minimum punch radius, distribution of stresses during bending, maximum bending load, and amount of over-bending required to account for elastic springback after forming.

Uploaded by

prasanna
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Lecture 26: Plane Strain Bending of

Strips
Jayadeep U. B.
Dept. of Mechanical Engg., NIT Calicut.
Introduction
In this lecture, we consider the analysis of bending the strips for
getting a permanent curvature.
Thickness of the strip is assumed to be much lesser than the other
two dimensions.
The strip is very much longer than its width, and the problem can
be assumed to be of plane strain type.
The radius of curvature can be quite small, hence the standard
Euler-Bernoulli assumptions are not strictly valid. Specifically, the
shift in location of the neutral axis cannot be ignored.
Elastic recovery (spring-back) is very important in such an
application. Hence the elastic strains cannot be ignored.
Elastic and plastic strains are of comparable magnitude; we assume
a linear strain hardening material model.
2 ME6302 Metal Forming
Analysis Objectives and Assumptions
Objectives:
Determine the bending force, especially the maximum value.
Estimate the elastic spring-back, and the over-bending required.
Minimum radius of punch nose to avoid fracture.
Assumptions:
Plane strain condition.
Material is linear elastic linear strain hardening type.
A shift in location of neutral axis (equal to 5% of thickness) towards
the center of curvature.
All effects of curvature other than shift in neutral axis are ignored.
No thinning or thickening of the workpiece.

3 ME6302 Metal Forming


Schematic Diagram of Bending
Punch nose and
corners of the die are
provided with
sufficient radii to
prevent fracture.
The die center has a
radius higher than
the punch nose.
Bending force F is
maximum at some
intermediate stage.

4 ME6302 Metal Forming


Punch Radius
Algebraically highest strain occurs in the outer fiber of the bend,
where cracks will originate.
Assuming a shift in neutral axis equal to 5% of the strip thickness
towards the center of curvature, we get:
( rp + t ) ( rp + 0.45t ) 1
max = ln 1 + = ln 1 +
( rp + 0.45t ) 1.82 ( rp t ) + 0.82
For a given material, there exists a maximum value of strain,
beyond which fracture takes place.
Equating max to the allowable strain, minimum value of punch
radius (rp) can be calculated.

5 ME6302 Metal Forming


6
Determination of Work Load
We ignore all effects of small radius of curvature, except the shift
in neutral axis.
The material is isotropic; specifically the yield strength in tension
and compression are the same.
Plastic deformation starts when the stress at a point reaches the
initial yield strength.
After some plastic deformation has occurred, stress distribution
will be as in figure (a), which can be idealized as shown in (b).
Stresses are different in the inner and outer fibers of the strip due
to shift in neutral axis and strain hardening:
Y1 = Y0 + n max
p
= Y0 + n ( max Y0 E ) ; n is the rate of strain hardening.
( rp + 0.45t ) rp 1
Y2 = Y0 + n ln 1 + Y0 E = Y0 + n ln 1 + Y0 E
( rp + 0.45t ) 2.22 ( rp t ) + 1
7
Determination of Work Load contd.
The resultant of this stress distribution is an axial force P and a
bending moment M (H.W.):
2 Y0 Y1 2 Y0 Y2
M = ( 0.55t ) + + ( 0.45t ) +
6 3 6 3
t
P = [ 0.2 Y0 + 0.55 Y1 0.45 Y2 ]
2

Consider the right half of the job:


P can be ignored as it is very small.
Forces from punch and die can be
approximated as line forces.

ME6302 Metal Forming


8
FBD of right half of the job
Determination of Work Load contd.
Since thickness of strip is small in comparison with other
dimensions, moment contribution from frictional forces is
negligible. Hence, M = Nl/cos .
The bending force per unit width is given by:
F 2 = N cos + N sin F = 2 N ( cos + sin )
Substituting for N: F = ( 2M l ) ( cos 2 + sin cos )
Differentiating: dF d = ( 2M l )( sin 2 + cos 2 )
F reaches a maximum value, when: = cr = ( tan 1 ) 2
Thus the maximum work load per unit width is,
1 + cos ( tan 1 ) + sin ( tan 1 )
M
Fmax =
l
9 ME6302 Metal Forming
Estimation of Spring Back

OA is the path of initial loading and AB is the unloading path.


The maximum recovered strain is rec = BC = A E
This can be assumed to be due to negative bending moment:
M E E ML
10 ME6302 Metal Forming = = = is the spring back.
I R L EI
Estimation of Spring Back contd.
With original included angle (for half portion) /2, 2 = 2ML
EI
With a 5% shift in neutral axis, = L
2 (r p + 0.45t )
2 M ( rp + 0.45t )
Substituting, =
EI

For a rectangular cross-section with unit width,


t3 2 12 ( rp + 0.45t ) M
I= =
12 Et 3
Therefore, the punch angle should be ( 2 ) to produce a bend
with an included angle .

11 ME6302 Metal Forming


References
Hosford, W.F. and Caddell, R.M., Metal Forming, Cambridge
University Press.
Dieter, G.E., Mechanical Metallurgy, McGraw Hill.
Ghosh, A. and Mallick, A.K., Manufacturing Science,
East West Press.
Hoffman, O. and Sachs, G., Introduction to the Theory of
Plasticity for Engineers, McGraw-Hill Book Company.
Hill, R., The Mathematical Theory of Plasticity, Oxford University
Press.
Johnson,W. and Mellor, P.B., Plasticity for Mechanical Engineers,
van Nostrand Company Ltd.

12 ME6302 Metal Forming

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