Air-Vee bending

Mohak Patel

2nd September, 2011 9003045

Aim To study the Air-Vee Bending of sheet metal strip and calculate its springback and its dependence on the process parameters. Theory As in any bending the inner fibers are in compression and the outer fibers are in tension.The minimum bend radius is usually stated in terms of the sheet thickness ( ex. 2T, 3T etc) Bending terminology: the bend radius is measured to the inner surface of the bend. Note the length of the bend is the width of the sheet. Also, the bend angle and the bend radius are two different variables.

Cracking during bending is related to the direction in which the sheet has been rolled, as shown in the figure below.

Springback is an elastic recovery of a material after unloading in plastic deformation. Terminology for Springback in bending. Springback is caused by the elastic recovery of the material upon unloading. In this example, the material tends to recover to its original flat shape. However there are cases, when the material bends farther upon unloading (negative springback).

The springback is usually compensated by overbending. Predicting springback precisely during die design is key to obtaining a tight part tolerances and controlling the process. Springback must be predicted and the punch position adjusted accordingly. It is difficult for engineers to predict the springback because many variables affects it, such as material properties IE, yield strength , plastic properties, tool geometry, sheet thickness, angle and radius of the bend, die gap and the punch stroke. However as a simple rule, the smaller the bend radius, the smaller the springback and greater the bending angle the smaller the springback. In air-vee bending operation the sheet is supported by two shoulders of a stationary die. The die is designed deep enough to prevent the punch and the workpiece from bottoming out. The required bending angle is determined by die opening and punch displacement (stroke) and there is no need to change equipment/dies to obtain different bend angles. Formula Springback can be calculated using the following formula: ( ) ( )

Procedure 1. The air bending is carried out on a fly press. It is easier to operate and to change its stroke. A simple open die, with an adjustable die gap and a punch are used for free vee bending of sheet metal strips of steel and aluminium. There is no bottoming. 2. While the stell is in a loaded condition, before withdrawing the punch, the angle of bend is measured geometrically by tracing the deformed sheet profile onto a transparency sheet. The sheet profile is also traced after unloading, i.e., after springback has occurred. 3. Bending is carried out at different punch strokes and die openings. Data Aluminium Mild Steel E Y E Y 69 GPA 275 MPA 200 GPA 245 MPA

Observation Material 1: Aluminium, Thickness = 2.56mm Punch Stroke (mm) 5 15 25 Initial Bend Angle Final Bend Angle, 1525 5050 8240 Springback angle Bend radius (mm) 1745 5120 8625 220 30 345 26 14 12 Bend radius (mm) 28 15 14

Sr. No. 1 2 3

Theoretical (mm) 29.585 14.979 12.712

Material 2: Mild Steel, Thickness = 2.12mm Punch Stroke (mm) 5 15 25 Initial Bend Angle Final Bend Angle 1430 4915 8130 Springback Angle Bend radius (mm) 1825 5505 8655 355 550 525 29 13 12 Bend radius (mm) 30 15 14

Sr. No. 1 2 3

Theoretical (mm) 30.259 13.247 12.210

Conclusion 1. The observed bend radius was found to be close to the theoretical bend radius. 2. No clear pattern was observed in spring back angle and punch stroke. 3. Bend angle and bend radius not only depend on the punch stroke but also on the time till which the punch is pressed, this factor was not included while calculating the springback angle. Sources of Error 1. Human error arising while tracing the deformed steel profile on paper. 2. Error in giving a particular value of punch stroke. 3. Error arising due to neglecting the effect of time on deformation of the plate. Suggestions to improve the experiment: 1. Time of the punch stroke should be considered for this experiment. 2. Some other method should be used for tracing the profile of the deformed steel