On the Springback and Load in Three-Point Air Bending of the AW-2024 Aluminium Alloy Sheet with AW-1050A Aluminium Cladding

Abstract

This article presents the results of an analysis of the bending load characteristics and the springback phenomenon occurring during three-point bending of 1.0 and 2.0 mm thick AW-2024 aluminium alloy sheets with rolled AW-1050A cladding. A new proprietary equation was proposed for determining the bending angle as a function of deflection, which takes into account the influence of the tool radius and the sheet thickness. The experimentally determined springback and bending load characteristics were compared with the results of numerical modelling using different models: Model I, a 2D model for a plane deformation state, disregarding the material properties of the clad layers; Model II, a 2D model for a plane deformation state, taking into account the material properties of the cladding layers; Model III, a 3D shell model with the Huber–von Mises isotropic plasticity condition; Model IV, a 3D shell model with the Hill anisotropic plasticity condition; and Model V, a 3D shell model with the Barlat anisotropic plasticity condition. The effectiveness of these five tested FEM models in predicting the bending load and springback characteristics was demonstrated. Model II was the most effective in predicting bending load, while Model III was the most effective in predicting the amount of springback after bending.