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Air Vee Bending (AVB)

To study the Air Vee Bending of metal strips of various materials and compare their springback with theoretical springback.

Theory of Operation
Springback predictions are important to maintain the geometric tolerance of the finished part. Springback refers to the elastic recovery of the non-uniformly distributed stresses in a deformed part after the forming load is removed. In bending the outer fibers will be in tension where as inner fibers will be in compression. The stress profile looks like as shown in fig given below.

The unloading is always elastic. The loading unloading curve for elasto-plastic deformation looks like in figure give below.

ME-311, IIT Gandhinagar

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The typical stress curve in case of elasto-plastic bending is shown in the part 1 of figure below. The unloading has been shown in part 2. The unloading is always elastic. The residual stresses are shown in the part 3 of the figure.

The terminology of air vee bending is given below.

Springback can be calculated from the formula = +

The air vee bending is carried out on simple open die. The bottoming is absent. The metal strips are placed onto die and punch is used to bend sheets up to desired radius. The profile of sheet is being traced onto paper. The radius of curvature and bend angle is then measured from the trace on the paper. Now the punch is released and the final profile is traced on paper. The final radius of curvature and final bend angle is then measured from the trace on the paper.

Ri=initial radius of curvature Rf=final radius of curvature (after springback) Page 2

ME-311, IIT Gandhinagar

i=initial bend angle f=final bend angle (after springback) =springback

Observation Table
Material 1: Aluminum, Thickness = 2.56mm
Sr 1 2 3 Sr 1 2 3 Punch Stroke (mm) 5 15 25 Punch Stroke (mm) 5 15 25 i 1745 5120 8625 i 1825 5505 8655 f 1525 5050 8240 f 1430 4915 8130 = f- i 220 30 345 = f- i 355 550 525 (mm) 26 14 12 (mm) 29 13 12 (mm) 28 15 14 (mm) 30 15 14 Rf (expected) (mm) 29.585 14.979 12.712 Rf (expected) (mm) 30.259 13.247 12.210

Material 2: Mild Steel, Thickness = 2.12mm

E Aluminum = 69 GPa YAluminum = 275 MPa EMild Steel = 200 GPa YMild Steel = 245 MPa

Possible Errors
The time for bending was not constant. Measurement of punch stroke by external scale by manual process. Inconsistent thickness of metal strips.

The final bend angle after springback is smaller. The final radius after springback is larger.

-Vrushiket Patil(09003044) Mechanical Btech 2009 Date: 9 / 9 / 2011

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