Study of springback pattern of non-uniform thickness section based on V-bending experiment

Abstract

Non-uniform thickness section is one of most effective approaches in reducing automotive part weight. Less weight results in less fuel consumption and therefore good for the environment. Formability is the main issue of non-uniform thickness section, since changes in thickness may cause parts to behave distinctively compared to uniform thickness during the forming process. One of the main concerns is the springback pattern. This study focused on springback behaviour of AA6061 strip with non-uniform thickness through V-bending experiment. The outcome will contribute in the manufacturing of automotive parts with non-unifrom thickness, where defects such as springback can be predicted and minimised. In the experiment, three parameters i.e. thickness ratio, bend radius and alignment were studied and the effects were observed. The result found that thickness was the most influential parameters compared to others. Thickness was reduced through cold deformation, causing the hardness to increase and then resulted in higher springback value. The effect of alignment was almost negligible. Validation made based on the result found is in agreement with prior published works.

Keywords

• weight reduction
• non-uniform thickness
• springback
• thickness ratio