Springback trends with different process parameters and with the mechanical properties of three selected metals

Abstract

Products or components manufactured by the sheet metal process are indispensable in this contemporary era, from daily-used metal jars to high-tech air vehicles. Nonetheless, there are a variety of sheet metal manufacturing processes for fabricating these goods; the air-bending sheet metal process is one of the most commonly conducted methods among those. After air bending, commonly used metals — Mild Steel, Aluminum, and Stainless Steel — tend to demonstrate an unwanted characteristic called springback, which requires being controlled to produce extremely precise parts. Therefore, this study aimed to develop an empirical model that would improve springback prediction which would ultimately assist in minimizing the springback effect in bending operations. Moreover, exploring springback trends with process-related parameters and metal’s mechanical properties was also the goal of this work. To achieve objectives thoroughly, several methodological approaches were incorporated sequentially: Box-Behnken experimental design, experimental data collection, conducting an ANOVA test, empirical model selection, model development, and model validation. For pursuing these approaches, the Design Expert^® software, Universal Testing Machine, and Bevel Protector were utilized. Finally. in the validation phase, it was found that the developed linear models were able to prognosis springback with acceptable errors. From that mathematical model, springback trends with process-related parameters were explored. Moreover, that mathematical model was also useful revealing springback trends with proven mechanical properties of selected metals. Overall, this study provides a wider view for observing springback trends with different factors.