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Materials Today: Proceedings 5 (2018) 4353–4358 www.materialstoday.com/proceedings

ICMPC 2017

Study of factors affecting Springback in Sheet Metal Forming and

Deep Drawing Process
Radha Krishna Lal1*, Vikas Kumar Choubey2, J. P. Dwivedi3
& Shravan Kumar 4
1,4
Department of Mechanical Engineering, Madan Mohan Malaviya University of Technology,
Gorakhpur-273010, Uttar Pradesh, India
2
School of Mechanical Engineering, Galgotias University,
Greater Noida, Uttar Pradesh, India
3
Department of Mechanical Engineering, Indian Institute of Technology(Banaras Hindu University),
Varanasi-221005, India

Abstract

Spring back is the most important phenomenon that affects the accuracy of the sheet metal parts. the important problem because
spring back is major forming defect in sheet metal forming using high strength steel sheets. Spring back occurs in metal forming
after removal of the load due to elastic recovery of material. It is difficult to develop analytical formula for spring back the
formed parts it is highly recommended to use such process parameter, tool geometry that are allow a significantly dimension of
the spring back amount of the major defects in sheet metal forming processed. Spring back is influenced by many factors
including properties of the sheet materials and processing conditions, Obtaining the desired size, shape depends on the prediction
of spring back. By analyzing these parameters, the defects like wrinkling, earing, tearing and spring back is reduced and also we
can get the very good quality product.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.

Keywords: spring back; sheet metal forming; deep drawing

* Corresponding author. Tel.: +919450533073

E-mail address :rkl.iitbhu@gmail.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.
4354 Radha Krishna Lal et al. / Materials Today: Proceedings 5 (2018) 4353–4358

1. Introduction

Sheet metal forming is the most commonly used manufacturing processes in industry production it is used to
change the geometry of sheet metal of normally about 7mm thickness without loss of material [1]. This is widely use
can be attributed to the effortlessness with this a wide range of products can be produced using the method, connect
with its adaptability to new manufacturing technologies such as hydro forming. Sheet metal forming operations
consists of simple bending, ironing, wheeling, stretch and roll forming, rubber-pad forming, stamping, flanging,
spinning, embossing, hyper-plastic and peen forming, explosive and magnetic-pulse forming and deep drawing of
complex parts [2]. Deep drawing is the common sheet metal forming process and it is mostly used in the
automotive, packaging and home and kitchen appliance production industries. Deep drawn automotive components
such as outer car body panels, inside car body panels, fender and different stiffeners are the examples. The common
products for packaging that are made up of sheet metal forming processes include pet geysers, food containers cans,
beverage containers cans and toe cups[3-6]. Some home appliances and kitchen appliances that are produced using
sheet metal forming consist as sinks in kitchen, pots and pans. The objective of sheet metal forming processes is first
and foremost to produce a desired shape of the product by plastic deformation. The final product quality is
dependent on not only the sheet material characteristics but also process variables such as stress, strain, strain rate
and temperature and also depend working condition,These variables are affected by the tool geometry and design
properties of the lubricant used and drawing speed [7].
Bending processes are used to form the sheet metals. These are very importent processes used in the
manufacturing of panels electronic components, drums, components of automobile vehicle etc. The major problem
in bending process is the spring back or spring-go. The spring back is a complex phenomenon and it depends on
process parameters and material parameters. A lot of research has been done to investigate the parameters affecting
spring back and to reduce spring back. In every industry, quality and productivity are major issues for being
competitive. For example, a car frame needs to be designed to achieve strength requirements and aesthetic aspects;
on the other hand, cost of production and repeatability is crucial to the business[8]. A stamping process has been one
solution used in practice to achieve these goals in the sheet metal fabrication business. Lal et al [9-19] Analysis the
Springback of different cross sectioned bar of linear and non linear work- hardening materials under torsional
loading.

There was also considerable research in the area of the establishment of the possible influence of algorithmic and
numerical aspects of the simulation on the corresponding results. These include the material model , the integration
scheme , the element type , process conditions , and the solution procedure. To this end, relatively simple forming
processes such as draw-bending or deep drawing of a cylindrical cup are utilized. A typical spring back simulation
consists mainly of two parts: The deep drawing process followed by the computation of the elastic spring back. The
deep drawing part is highly developed and yields reliable results.

2. Deep drawing process

The Deep drawing is one of the commonly applied process in sheet metal forming. Deep drawing operation is
based on manufacturing engineering parts with particular shapes and size through major plastic deformation of
mainly used flat metal sheets. An external forceare applied on a flat metal sheet makes this plastic deformation.
This external force has to be high enough to transfer the material in the plastic zone and it has to ensure that after
displacing the external force, the final metal part doesn't spring back or elastic deform again[4]. At last the final
quality of the parts produced by deep drawing operation is based on the final wall thickness and being wrinkle-free
and fracture-free surface. Schematic diagram of deep drawing process is shown in Fig.1
 Radha Krishna Lal et al./ Materials Today: Proceedings 5 (2018) 4353–4358 4355

Fig.1 Deep drawing opration [2].

3. Principle of spring back

The elastic stresses remaining in the bend area after bending pressure is released will cause a slight decrease in
the bend angle. Metal movement in this type is known as spring back, as shown in figure 1. The magnitude of the
movement will vary according to the material type, thickness and hardness. A larger bend radius will also known
grater spring back. Commercially available finite element analysis (FEA) software is used to analyze bending and
spring back of different aluminum materials of different thickness. For forming process the material is stressed
beyond elastic limit so that the permanent deformation takes place [5]. The material state becomes the plastic
deformation zone; hence the sheet metal can be formed. Figure 2 shows the principle of spring back.

Figure 2. Principle of Spring back θ1> θ2 or (Qf>Qi) [6].

Basically, the measurement of the springback refers to the fundamental theory of the bending process itself. The
springback amount can be measured by a springback angle (Δߠ), which can be calculated using the following
equation.
Δߠ= ߠ݅− ߠ݂
4356 Radha Krishna Lal et al. / Materials Today: Proceedings 5 (2018) 4353–4358

4. Effect of ratio of die radius and the sheet metal thickness on spring back angle

Aysun Egrisogut Tiryaki et al. [4] studied the effect the ratio of die radius and thickness of the sheet. Ratio of
the die radius and thickness of the sheet verses spring back angle, are plotted as shown in the figure 3. It is seen that
after certain level the spring back effect increases as the R/t ratio increases. In order to seen the effect of die radius
and blank thickness on the spring back angle of flanging process, the following strategy was employed. Two groups
of FE simulation models are generated with the identical R/t ratio that range between 1.0 and 5.0.

Fig-3 Effect of R/t on Spring back angle [8].

5. Effect of sheet thickness on spring back

The effect the sheet thickness on spring back is shown in the figure 3. Here the comparison of the experimental
and the Fem result. It is seen that the spring back increases as the sheet thickness increases, The effect of sheet
thickness on spring back on deep draw steel (IS 1079-1994) is studied and keeping all other affecting variable
parameters constant[7].

6. Conclusion

It is seen from the above review that the spring is dependent on the various parameters such as ratio of die radius
to sheet thickness, sheet thickness. blank holder force etc Spring back percentage in deep drawing process was
studied numerically by means of commercially used FEA software. The significance of some important process
parameter such as initial blank thickness, blank holder force(BHF), punch profile radius (RP), spring back of the cup
produced by deep drawing process were investigated. The numerical results obtained shows that by increasing the
value of the initial blank thickness reduced the spring back of the deformed sheet. Also, with increasing blank holder
force (BHF), the spring back will be decreased. And if excessive increasing of blank holder force (BHF) may cause
tearing of sheet. With the increasing of punch nose radius, the spring back was also increases. This study we
observed the spring back and other parameter are affected by the spring back.
 Radha Krishna Lal et al./ Materials Today: Proceedings 5 (2018) 4353–4358 4357

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Work-Hardening Materials under Torsional Loading”, “5th International Conference on Materials Processing and
Characterization, (ICMPC 2016)” during March 12 -13, 2016 at GRIET, Hyderabad.
[12] Radha Krishna Lal, Amit Prakash, Vikas Kumar Choubey , J. P. Dwivedi & V.P. Singh “Springback analysis of
I Sectioned bar of Linear Work- Hardening Materials under Torsional Loading”, “5th International Conference on
Materials Processing and Characterization, (ICMPC 2016)” during March 12 -13, 2016 at GRIET, Hyderabad.
[13] Radha Krishna Lal, Vikas Kumar Choubey , J. P. Dwivedi, V.P. Singh & S. K. Srivastava “Springback analysis
of Triangular Cross-sectioned Bar of Non-Linear Work- Hardening Materials under Torsional Loading”, “5th
International Conference on Materials Processing and Characterization, (ICMPC 2016)” during March 12 -13, 2016
at GRIET, Hyderabad.
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Analysis in Sheet Metal Forming of Non-linear Work-Hardening material under Pure Bending”, Journal of The
Institution of Engineers (India): Series C. (in press)
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Triangular Cross-sectioned Bar of Linear Work- Hardening Materials under Torsional Loading”, “5th International
Conference on Materials Processing and Characterization, (ICMPC 2016)” during March 12 -13, 2016 at GRIET,
Hyderabad.
[16] Radha Krishna Lal, Vikas Kumar Choubey, Sandeep Dwivedi, J. P. Dwivedi and V.P. Singh “Residual Stress
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[17] Radha Krishna Lal, Vikas Kumar Choubey, J.P. Dwivedi, V.P. Singh, (2016) "Springback analysis of channel
cross-sectioned bar of work-hardening materials under torsional loading", Engineering Computations, Vol. 33 Iss: 7,
pp.1899 – 1928.
4358 Radha Krishna Lal et al. / Materials Today: Proceedings 5 (2018) 4353–4358

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Forming Using Modified Ludwik Stress-Strain Relation,” ISRN Mechanical Engineering, vol. 2013, Article ID
640958, 11 pages, 2013. doi:10.1155/2013/640958
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Forming of Non-linear Work-Hardening material Under Pure Bending”, Journal of The Institution of Engineers
(India): Series C, DOI 10.1007/s40032-016-0333-y., September 2016