A Numerical Modelling of V-Bending

Abstract

In the study, a sheet metal is bent to analyze the punch force, Von Misses stresses and plastic strains on the metal for friction and non-friction cases. The 2-D v-bending forming is modelled in program. Model includes a die, a punch and a blank. Solid mechanics physics interface has been used in program. The analyze has been run with friction and non-friction cases for different strain-hardening exponents and sheet metal thicknesses. The sheet lengths and widths are 60 mm. Thickness of sheet metal is varied between 1.0 to 3.0 mm. The strain hardening exponent has been altered from 0.1 to 0.5. It is computed that the punch force has been increased as thickness of sheet metal and strain hardening exponent decreases. The achieved maximum punch force is at values of 1.12x105 N, 3.75x105 N and 4.05x105 N for thickness of 1.0-mm, 2.0-mm and 3.0-mm respectively when strain hardening exponent is 0.3. Also, as the strain hardening exponent increases from 0.1 to 0.5, the maximum punch force lowers from 2.03x105 N to 8.08x104 N for 1 mm thickness at friction case. Moreover, the maximum punch force reached up to 9.13x104 N for 1 mm thick sheet metal at non-friction case when the strain hardening exponent is 0.1. It is concluded that the maximum Von Misses stress has been calculated at the tip of sheet metal.