An inverse routine to predict residual stress in sheet material

Abvabi, Akbar; Rolfe, Bernard; Hodgson, Peter; Weiß, Matthias

doi:10.1016/j.msea.2015.11.077

Cited by 10 publications

(4 citation statements)

References 24 publications

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“…WEISS et al [20] and ABVABI et al [21,22] indicated that the product quality of sheet metal may be affected by the pre-existing residual stress during bending forming. LIN et al [23] demonstrated that both residual stress and thickness have major effect on sheet metal's springback.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation

Zhang,

2024

Int J Adv Manuf Technol

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Press-braking bending is usually performed after face milling to obtain the speci ed curvature of variety mechanical parts, which is widely applied in the aircraft manufacturing. The surface layer residual stress on workpiece caused by milling has an important in uence on subsequent forming. The in uences of surface residual stress caused by milling operation on press-braking bending has been investigated analytically and experimentally in this study. The analytical model for springback prediction based on plane strain assumption is proposed using the material model of Mises yield criterion and Swift exponential hardening law, and takes into account of the effects of milling-induced residual stress. Three levels of residual stress are introduced in the test plates through milling operation with different cutting speed. The analytical results are compared with the bending experiments of 7050-T7451 Al-alloy plates. Results show that the accuracy of the contour obtained by the proposed model is improved when surface residual stress is considered. Furthermore, the in uence of surface residual stress on springback is discussed. It is revealed that surface tensile residual stress increases springback and surface compressive residual stress contributes positively to the nal shape of bent specimens.

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Section: Introductionmentioning

confidence: 99%

Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation

Zhang,

2024

Int J Adv Manuf Technol

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“…For the multi-step pressbrake bending, the existence of the initial residual stress aroused from the previous bending step will affect the stress and strain distribution of the next-pass bending step, which will affect the springback behavior of the material after unloading, and finally affect the final forming quality of the workpiece. 10 Weiss et al 11 and Abvabi et al 12,13 demonstrated that the pre-existing residual stress could affect the product quality in a sheet metal forming such as bending and roll forming. Lin et al 14 proved that both residual stress and thickness have significant influence on sheet metal's springback.…”

Section: Introductionmentioning

confidence: 99%

Residual stress analysis and its effect on springback for multi-step pressbrake bending

Zhang

Tian

Wang

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Pressbrake bending is a multi-step metal forming process and widely applied in the fields of aerospace, shipbuilding, and offshore industry. However, the bending residual stress that arise from the previous-pass bending step will affect the stress distribution of the next-pass bending step, and finally affect the springback after unloading, which results in the difficulty to guarantee the dimensional accuracy of the forming part. In this study, the residual stresses for multi-pass pressbrake forming and its influence on springback are systematically investigated. First, the analytical model for the residual stress of the bent specimen with initial curvature is deduced based on geometric relationship and elastic–plastic bending theory. Second, the calculation method of rigid body position redefine to simulate the multi-pass bending forming process is developed, and the numerical method is confirmed by comparison with experimental method. The analytical model to predict the residual stress is shown to be in close agreement with results from numerical method, demonstrating the validity of the analytical model. Finally, the impact of residual stress in single-pass and multi-pass bending forming on springback are discussed thoroughly. It is found that, as the number of forming passes increases, the equivalent plastic strain will increase to 9% of three-pass loading from 7.8% of one-pass loading, which explains the reason of increasing the number of bending passes can not only reduce springback, but also reduce the residual effect of bending forming.

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“…Lopez et al [12] developed the application of the well-known laser ranging techniques in flatness inspection and construction and the testing of a flatness measurement and inspection system capable of acquiring the true shape of a steel strip in real-time, leading to calculating its flatness indexes so they can be used in the quality inspection of the steel products. Abvabi et al [13] found an inverse technique that could be used to obtain the residual stress profile and material constants. This technique provided the best fit in a finite element analysis of bend-ing with the experimentally derived moment curvature relation.…”

Section: Introductionmentioning

confidence: 99%

Regression Approach to a Novel Lateral Flatness Leveling System for Smart Manufacturing

Tsai

Chang

2021

Applied Sciences

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Sheet metal coils are widely used in the steel, automotive, and electronics industries. Many of these coils are processed through metal stamping or laser cutting to form different types of shapes. Sheet metal coil leveling is an essential procedure before any metal forming process. In practice, this leveling procedure is now executed by operators and primarily relies on their experience, resulting in many trials and errors before settling on the correct machine parameters. In smart manufacturing, it is required to digitize the machine’s parameters to achieve such a leveling process. Although smart manufacturing has been adopted in the manufacturing industry in recent years, it has not been implemented in steel leveling. In this paper, a novel leveling method for flatness leveling is proposed and validated with data collected by flatness sensors for measuring each roll adjustment position, which is later processed through the multi-regression method. The regression results and experienced machine operator results are compared. From this research, not only can the experience of the machine operators be digitized, but the results also indicate the feasibility of the proposed method to offer more efficient and accurate machine settings for metal leveling operations.

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An inverse routine to predict residual stress in sheet material

Cited by 10 publications

References 24 publications

Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation

Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation

Residual stress analysis and its effect on springback for multi-step pressbrake bending

Regression Approach to a Novel Lateral Flatness Leveling System for Smart Manufacturing

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