Evaluation of Spring Back Phenomenon Existing in Metals: Numerical Modeling and Mathematical Simulations

EasyChair Preprint 15437

Abstract

^{Spring back phenomenon (SBP) is considered a common issue facing engineers in automotive, ship, and aircraft manufacturing domains reflected in deformations that occur to the metal after the mold loading is removed. For these disciplines, ultimate scales of precision and efficiency in formulating the metal are needed since they cover the outer surface of the mechanical system, like automobiles, ships, and aircrafts. Thus, any small faults or irregularities in the metal’s outer surface might be massive if it correspond to larger drag forces and friction affecting the aerodynamic efficiency. Accordingly, this article investigates SBP behaviors in three metals that are exploited heavily in manufacturing, namely aluminum, copper, and pure steel. Corresponding mathematical simulations are implemented by finite element analysis (FEA) in ANSYS®. The core research outcomes revealed that the SBP (elastic recovery percentage) increased after removing the applied mold loading as the punch die radius increases. The SBP relies on the size of the plastic deformation zone. As the punch radius increases, the force spreads to a large plastic area; thus, increasing the SBP. Also, as the punch radius increases, the contact angle and contact area would increase. Hence, SBP could create more friction surface between the punch and the sheet. Pure steel and copper showed larger elastic recovery ratios after removing the mold load than aluminum across all thicknesses. Greater punch radii of the contact area between the punch and the sheet would become greater. Thus, the bending moment would escalate, causing a larger spring back angle. The SBP is much lower in ductile metals than in hard metals because of different Young’s modulus.}

Keyphrases: Aerodynamic performance, Finite Element Analysis (FEA), Manufacturing, Sheet Metal Forming (SMF), Spring back phenomenon (SBP), mold loading

@booklet{EasyChair:15437,
  author    = {Elham Abdullah and Abdulkareem Jalil},
  title     = {Evaluation of Spring Back Phenomenon Existing in Metals: Numerical Modeling and Mathematical Simulations},
  howpublished = {EasyChair Preprint 15437},
  year      = {EasyChair, 2024}}