Skip to main content
SpringerLink
Log in

Springback Reduction by Using Tool Rollers

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

Springback is defined as a geometric defect, which occurs due to elastic recovery in the part after it has been unloaded. This challenge is most common in lightweight alloys as well as in advanced high strength steels. The materials, which exhibit lower elastic modulus or higher tensile strength, would be more prone to springback. In this paper, a novel patented technique is introduced to eliminate the springback by using rollers in the forming tool. It was found that due to the rotation of rollers in the tool during forming, reduces the stress in the part and, thus reduces the springback.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Abbreviations

YS:

Yield Strength, MPa

TS:

Tensile Strength, MPa

%EL:

Percentage Elongation

K:

Strength Coefficient, MPa

n:

Strain Hardening Exponent

40CCW:

40 Roller rotations in counter clockwise direction

80CCW:

80 Roller rotations in counter clockwise direction

40CW:

40 Roller rotations in clockwise direction

References

  1. Hilditch, T. B., Speer, J. G., & Matlock, D. K. (2007). Influence of low-strain deformation characteristics of high strength sheet steel on curl and springback in bend-under-tension tests. Journal of Materials Processing Technology,182(1–3), 84–94.

    Article  Google Scholar 

  2. Wagoner, R. H., & Li, M. (2007). Simulation of springback: Through-thickness integration. International Journal of Plasticity,23(3), 345–360.

    Article  Google Scholar 

  3. Cheng, H. S., Cao, J., & Xia, Z. C. (2007). An accelerated springback compensation method. International Journal of Mechanical Sciences,49(3), 267–279.

    Article  Google Scholar 

  4. Wagoner, R. H., Lim, H., & Lee, M. G. (2013). Advanced issues in springback. International Journal of Plasticity,45, 3–20.

    Article  Google Scholar 

  5. Narasimhan, N., & Lovell, M. (1999). Predicting springback in sheet metal forming: An explicit to implicit sequential solution procedure. Finite Elements in Analysis and Design,33(1), 29–42.

    Article  Google Scholar 

  6. Li, K. P., Geng, L. M., & Wagoner, R. H. (1999). Simulation of springback with the draw/bend test. In Proceedings of the 2nd international conference on intelligent processing and manufacturing of materials, vol. 1. IPMM’99. IEEE, 1999.

  7. Gau, J. T., & Kinzel, G. L. (2001). A new model for springback prediction in which the Bauschinger effect is considered. International Journal of Mechanical Sciences,43(8), 1813–1832.

    Article  Google Scholar 

  8. Lee, S. W., & Kim, Y. T. (2007). A study on the springback in the sheet metal flange drawing. Journal of Materials Processing Technology,187, 89–93.

    Article  Google Scholar 

  9. Mori, K., Akita, K., & Abe, Y. (2007). Springback behaviour in bending of ultra-high-strength steel sheets using CNC servo press. International Journal of Machine Tools and Manufacture,47(2), 321–325.

    Article  Google Scholar 

  10. Lobdell, M. A., Nikhare. C. P., & Roth. J. T. (2013). An electric touch for aluminum springback elimination. In Proceedings of international deep-drawing research group, Zurich, Switzerland.

  11. Hill, R. (1948). A theory of the yielding and plastic flow of anisotropic metals. Proceedings of the Royal Society of London, Series A: Mathematical and Physical Sciences,193(1033), 281–297.

    Article  MathSciNet  Google Scholar 

  12. Barlat, F., Brem, J. C., Yoon, J. W., Chung, K., Dick, R. E., Lege, D. J., et al. (2003). Plane stress yield function for aluminum alloy sheets—Part 1: Theory. International Journal of Plasticity,19(9), 1297–1319.

    Article  Google Scholar 

  13. Chaboche, J. L. (1989). Constitutive equations for cyclic plasticity and cyclic viscoplasticity. International Journal of Plasticity,5(3), 247–302.

    Article  Google Scholar 

  14. Yoshida, F., & Uemori, T. (2002). A model of large-strain cyclic plasticity describing the Bauschinger effect and workhardening stagnation. International Journal of Plasticity,18(5–6), 661–686.

    Article  Google Scholar 

  15. Lee, M. G., Chung, K., Kim, D., Kim, C., Wenner, M. L., & Barlat, F. (2005). Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part I: Theory and formulation. International Journal of Plasticity,21(5), 861–882.

    MATH  Google Scholar 

  16. Zang, S. L., Guo, C., Thuillier, S., & Lee, M. G. (2011). A model of one-surface cyclic plasticity and its application to springback prediction. International Journal of Mechanical Sciences,53(6), 425–435.

    Article  Google Scholar 

  17. Larsson, R., Björklund, O., Nilsson, L., & Simonsson, K. (2011). A study of high strength steels undergoing non-linear strain paths—Experiments and modelling. Journal of Materials Processing Technology,211(1), 122–132.

    Article  Google Scholar 

  18. Eggertsen, P. A., & Mattiasson, K. (2009). On the modelling of the bending–unbending behaviour for accurate springback predictions. International Journal of Mechanical Sciences,51(7), 547–563.

    Article  Google Scholar 

  19. Yoshida. F. (2010). Material models for accurate simulation of sheet metal forming and springback. In AIP conference proceedings, vol. 1252, no. 1. AIP.

  20. Zhu, Y. X., Liu, Y. L., Yang, H., & Li, H. P. (2012). Development and application of the material constitutive model in springback prediction of cold-bending. Materials and Design,42, 245–258.

    Article  Google Scholar 

  21. Nikhare, C. P. (2016). Die for reducing springback and process there of. U.S. Patent No. 9,498,812. November 22, 2016.

  22. Grüebler, R., & Hora, P. (2009). Temperature dependent friction modeling for sheet metal forming. International Journal of Material Forming,2(1), 251–254.

    Article  Google Scholar 

  23. Klocke, F., Trauth, D., Shirobokov, A., & Mattfeld, P. (2015). FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: Development of a novel coupled user subroutine for shell and continuum discretization. The International Journal of Advanced Manufacturing Technology,81(1–4), 397–410.

    Article  Google Scholar 

Download references

Acknowledgements

Author would like to thank Penn State Erie, the Behrend College for undergraduate research scholarship, open lab research facilities and resources and Mr. Glenn Craig for tool manufacturing and specimen fabrication.

Author information

Authors and Affiliations

  1. Mechanical Engineering, The Behrend College, The Pennsylvania State University, Erie, PA, 16563, USA

    Chetan P. Nikhare

Authors
  1. Chetan P. Nikhare
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chetan P. Nikhare.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nikhare, C.P. Springback Reduction by Using Tool Rollers. Int. J. Precis. Eng. Manuf. 21, 67–74 (2020). https://doi.org/10.1007/s12541-019-00205-x

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-019-00205-x

Keywords

Search

Navigation