A Numerical Study on Springback of a Channel Through the Oscillation of Punch

Abstract To meet the demand of light weighting, environmental regulation, increase fuel economy, many innovations are underway. Options are light weighting the part to reduce the fuel consumption or decrease the gage in high strength dense material. In both cases during or after deforming the part these challenges occur like higher tonnage machine for deformation, sudden fracture, geometric defect, etc. One of the geometric defects which is very common in sheet metal forming is springback. Springback is the deviation of the part from the desired shape after the part is shaped and then load is released. It is the material tendency to relaxed back based on the accumulated strain and its elasticity. In lighter material or higher strength steels, the springback phenomena is very common due to lower elasticity or higher strength value. In this paper springback is analyzed by conceptualizing an innovative process. The innovative process is oscillation of the punch after the forming process is done. The 2D channel strip of the aluminum 2024 high strength alloy was used in the bending process. The process of bending with punch die and the blank was modeled in the ABAQUS finite element software. First, the conventional channel deformation was performed, and the deformation was studied and springback was compared with the desired shape. Then the oscillation of the punch was set either in the longitudinal or lateral direction. The frequency of the punch was also been changed to see the effect on the deformation behavior of the material and springback after the punch release. The residual stress during the process was studied and compared. Further the maximum stress, deformation of the channel and springback was analyzed and presented. It was found that the punch oscillation contributes in reducing the springback.