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Analysis of 6061 Aluminium Alloy Sheet Metal Bending Process for Various Thickness Using Finite Element Modelling

Received: 6 November 2016     Accepted: 17 November 2016     Published: 10 December 2016
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Abstract

This study elaborates the bending process of Al 6061 aluminium alloy using three-point bend test. The permanent deformation takes place on the sheet metal strip as a result of severe plastic strain. One of the major issues in the sheet metal bending process is that the formation of spring back during unloading. This study involves combined design of experiment and finite element analysis to understand the bending and spring back behaviour of sheet metal. The elasto-plastic behaviour is studied by parametric numerical simulations. The static mechanical behaviour at ambient temperature is investigated for various thickness and radius of punch to achieve its correlations. The systematic approach is carried by developing numerical models of three-point bending of aluminium strips.

Published in International Journal of Theoretical and Applied Mathematics (Volume 2, Issue 2)
DOI 10.11648/j.ijtam.20160202.20
Page(s) 93-99
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2016. Published by Science Publishing Group

Keywords

FEA, DOE, Bending, Manufacturing, Aluminium

References
[1] F. Zhou and G. Long, "Element interaction of cold-formed stainless steel cross-sections subjected to major axis bending," Journal of Constructional Steel Research, vol. 118, pp. 22-40, 2016/03// 2016.
[2] N. Tondini and A. Morbioli, "Cross-sectional flexural capacity of cold-formed laterally-restrained steel rectangular hollow flange beams," Thin-Walled Structures, vol. 95, pp. 196-207, 2015/10// 2015.
[3] D. Ayhan and B. W. Schafer, "Cold-formed steel member bending stiffness prediction," Journal of Constructional Steel Research, vol. 115, pp. 148-159, 2015/12// 2015.
[4] S.-l. Zang, M.-G. Lee, L. Sun, and J. H. Kim, "Measurement of the Bauschinger behavior of sheet metals by three-point bending springback test with pre-strained strips," International Journal of Plasticity, vol. 59, pp. 84-107, 2014/08// 2014.
[5] K. Lawanwomg, H. Hamasaki, R. Hino, and F. Yoshida, "A Novel Technology to Eliminate U-bending Springback of High Strength Steel Sheet by Using Additional Bending with Counter Punch," Procedia Engineering, vol. 81, pp. 957-962, 2014 2014.
[6] M. Fadden and J. McCormick, "Finite element model of the cyclic bending behavior of hollow structural sections," Journal of Constructional Steel Research, vol. 94, pp. 64-75, 2014/03// 2014.
[7] S. B. Chikalthankar, G. D. Belurkar, and V. M. Nandedkar, "Factors affecting on springback in sheet metal bending: a review," International Journal of Engineering and Advanced Technology (IJEAT), vol. 3, 2014 2014.
[8] R. H. Wagoner, H. Lim, and M.-G. Lee, "Advanced Issues in springback," International Journal of Plasticity, vol. 45, pp. 3-20, 2013/06// 2013.
[9] Y. X. Zhu, Y. L. Liu, H. Yang, and H. P. Li, "Development and application of the material constitutive model in springback prediction of cold-bending," Materials & Design, vol. 42, pp. 245-258, 2012/12// 2012.
[10] T. A. Hadi and T. Jusoh, "Design suitable punch or die to overcome springback on u-bending," Universiti Malaysia Pahang, 2012.
[11] S. Thipprakmas and W. Phanitwong, "Process parameter design of spring-back and spring-go in V-bending process using Taguchi technique," Materials & Design, vol. 32, pp. 4430-4436, 2011/09// 2011.
[12] R. C. Spoorenberg, H. H. Snijder, and J. C. D. Hoenderkamp, "Finite element simulations of residual stresses in roller bent wide flange sections," Journal of Constructional Steel Research, vol. 67, pp. 39-50, 2011/01// 2011.
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  • APA Style

    G. Pradeep Dev, P. Sam Livingston, M. Shunmuganathan, R. Surendar, A. Siva Subramanian, et al. (2016). Analysis of 6061 Aluminium Alloy Sheet Metal Bending Process for Various Thickness Using Finite Element Modelling. International Journal of Theoretical and Applied Mathematics, 2(2), 93-99. https://doi.org/10.11648/j.ijtam.20160202.20

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    ACS Style

    G. Pradeep Dev; P. Sam Livingston; M. Shunmuganathan; R. Surendar; A. Siva Subramanian, et al. Analysis of 6061 Aluminium Alloy Sheet Metal Bending Process for Various Thickness Using Finite Element Modelling. Int. J. Theor. Appl. Math. 2016, 2(2), 93-99. doi: 10.11648/j.ijtam.20160202.20

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    AMA Style

    G. Pradeep Dev, P. Sam Livingston, M. Shunmuganathan, R. Surendar, A. Siva Subramanian, et al. Analysis of 6061 Aluminium Alloy Sheet Metal Bending Process for Various Thickness Using Finite Element Modelling. Int J Theor Appl Math. 2016;2(2):93-99. doi: 10.11648/j.ijtam.20160202.20

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  • @article{10.11648/j.ijtam.20160202.20,
      author = {G. Pradeep Dev and P. Sam Livingston and M. Shunmuganathan and R. Surendar and A. Siva Subramanian and A. Simon Christopher and K. C. Ganesh},
      title = {Analysis of 6061 Aluminium Alloy Sheet Metal Bending Process for Various Thickness Using Finite Element Modelling},
      journal = {International Journal of Theoretical and Applied Mathematics},
      volume = {2},
      number = {2},
      pages = {93-99},
      doi = {10.11648/j.ijtam.20160202.20},
      url = {https://doi.org/10.11648/j.ijtam.20160202.20},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijtam.20160202.20},
      abstract = {This study elaborates the bending process of Al 6061 aluminium alloy using three-point bend test. The permanent deformation takes place on the sheet metal strip as a result of severe plastic strain. One of the major issues in the sheet metal bending process is that the formation of spring back during unloading. This study involves combined design of experiment and finite element analysis to understand the bending and spring back behaviour of sheet metal. The elasto-plastic behaviour is studied by parametric numerical simulations. The static mechanical behaviour at ambient temperature is investigated for various thickness and radius of punch to achieve its correlations. The systematic approach is carried by developing numerical models of three-point bending of aluminium strips.},
     year = {2016}
    }
    

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    AU  - G. Pradeep Dev
    AU  - P. Sam Livingston
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    AU  - R. Surendar
    AU  - A. Siva Subramanian
    AU  - A. Simon Christopher
    AU  - K. C. Ganesh
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    JF  - International Journal of Theoretical and Applied Mathematics
    JO  - International Journal of Theoretical and Applied Mathematics
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    UR  - https://doi.org/10.11648/j.ijtam.20160202.20
    AB  - This study elaborates the bending process of Al 6061 aluminium alloy using three-point bend test. The permanent deformation takes place on the sheet metal strip as a result of severe plastic strain. One of the major issues in the sheet metal bending process is that the formation of spring back during unloading. This study involves combined design of experiment and finite element analysis to understand the bending and spring back behaviour of sheet metal. The elasto-plastic behaviour is studied by parametric numerical simulations. The static mechanical behaviour at ambient temperature is investigated for various thickness and radius of punch to achieve its correlations. The systematic approach is carried by developing numerical models of three-point bending of aluminium strips.
    VL  - 2
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Author Information
  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, India

  • Department of Mechanical Engineering, University College of Engineering, Nagercoil, India

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