A new approach to reduce springback in sheet metal bending using digital image correlation

Abstract Springback caused by elastic recovery is known to be a major disadvantage in sheet metal forming. Many studies focused on the prediction and compensation of springback in the bending process have used simulation and numerical methods, with experimental tests rarely being reported. A new approach, aimed at decreasing springback, is presented in this paper to solve the springback problem and provide a reference for other researchers. A new edge bending method called “incremental bending” has been developed and implemented on aluminum sheet at room temperature. Using this method, bending strain was lowered, leading to a reduction in springback. 3D Digital Image Correlation, an optical measurement technique, was adopted simultaneously to provide a high accuracy measurement of the full field strain distribution and springback curvature, making it very suitable for springback measurement. The experimental results show an obvious reduction of springback, which agrees well with the theoretical analysis. This work could help to minimize springback in sheet metal bending dramatically and improve formability and productivity, as well as provide a reference for researchers studying cold-bending. Details of the basic bending theory, experimental method, experimental results, and analysis will be demonstrated in the following content.