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Experimental comparison of straight flanging and rotary die bending based on springback

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Abstract

Springback in sheet bending is a well-defined phenomenon; however, variation of springback is difficult to control causing quality problems in especially mass-produced goods such as home appliances. As an alternative to straight flanging, the rotary die bending process offers reduced springback as well as reduced geometric variation; however, there is little knowledge in the literature. The effects of process parameters on the springback behavior of straight flanging and rotary die bending as applied to home appliance side panels are investigated experimentally. For each flange bending method, effects of die radius, punch-die clearance, rolling direction, flange length, and material supplier on springback are tested on EN DC01 carbon and SAE 430 stainless steel sheets. A material-wise factorial experimental design was applied to investigate the factor interactions as well as the main effects using ANOVA. In both methods, die radius was the most dominant factor on springback, clearance being the second, and the inevitable material property variations being the third one. Nevertheless, in rotary die bending, springback values were smaller with significantly less scatter compared to straight flanging. Consequently, rotary die bending is a much more preferable process especially in mass production performed with narrow profit margins.

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Acknowledgements

The work presented in this article was conducted as the Master’s thesis of Salih E. Turan at the Department of Mechanical Engineering of Istanbul Technical University, being sponsored by Arçelik Corp. R&D Department Tuzla Istanbul, Turkey.

Funding

This article was internally supported by the R&D Department of Arçelik Corp. of Tuzla Istanbul Turkey.

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Authors and Affiliations

  1. Dept. of Mechatronics Engineering, Yıldız Technical University, İstanbul, Turkey

    Haydar Livatyali

  2. TEI - TUSAŞ Engine Industries, Eskisehir, Turkey

    Salih Emrah Turan

  3. Saglam Metal Co, Gebze, Kocaeli, Turkey

    Feriha Birol

  4. Dept. of Mechanical Engineering, Konya Technical University, Konya, Turkey

    Mevlüt Türköz

Authors
  1. Haydar Livatyali
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  2. Salih Emrah Turan
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  4. Mevlüt Türköz
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Contributions

This paper was generated from the Master’s thesis the co-author Mr. Salih E. Turan conducted and Dr. Haydar Livatyali supervised at the Department of Mechanical Engineering of Istanbul Technical University. Dr. Feriha Birol was the industrial mentor (co-adviser) representing the Arçelik Corp. Dr. Mevlüt Türköz repeated the statistical analysis for validation and co-authored the article.

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Correspondence to Haydar Livatyali.

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Livatyali, H., Turan, S.E., Birol, F. et al. Experimental comparison of straight flanging and rotary die bending based on springback. Int J Adv Manuf Technol 120, 4373–4386 (2022). https://doi.org/10.1007/s00170-022-09020-7

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