Simulation and Experimental Study of the V-Bending Process for SS304 and AA6061 Sheets Using Additively Manufactured Tools

Additive manufacturing (AM) is revolutionizing industrial manufacturing by introducing advanced techniques for designing and producing prototypes across various sectors. AM is increasingly being used to create cost-effective tools, such as blank holders, dies, and punches, that enhance the formability of sheet metal products. This study investigates the use of 3D-printed tools in the V-bending process, employing Finite Element Analysis (FEA) and experimental setups at angles of 30, 45, and 60 degrees. The formability of 1mm-thick SS304 steel and AA6061 aluminium was evaluated, focusing on geometric precision, thinning, and overall formability. FEA results suggest that increasing sheet thickness may reduce formability for both materials. Simulations were compared with permissible limits to ensure accurate samples. Experimentally, sixty samples were bent using dies and punches made from Acrylonitrile Butadiene Styrene (ABS). Results showed that the ABS material significantly influenced the bending process, indicating its potential for use in batch production. The findings highlight the feasibility of using AM-generated tooling to improve formability and optimize production in sheet metal forming.