Effects of Groove Depth and Sheet Thickness on V-Bending Process Predicted by Finite Element Analysis

Springback is a significant challenge that affects forming accuracy in the sheet metal industry. This phenomenon occurs because elastic materials tend to revert to their original shape after the removal of deforming forces, leading to differences between the desired and final shapes of the metal. Currently, two primary methods are employed to investigate springback: physical experiments and numerical simulations. Physical experiments involve actual deformation of sheet metals to observe and measure springback. While these experiments can provide useful data and insights, they are often time-consuming and expensive, making them less possible for extensive studies or frequent iterations. On the other hand, numerical simulations offer a virtual modeling platform that can predict and analyze springback without the need for physical trials. These simulations enable engineers to refine the metal forming process for better end-product accuracy. Building on these existing methodologies, this research uses ANSYS software to conduct Finite Element Analysis (FEA) and reconstruct simulation data for V-bending technique. This study first compares the reconstructed data with data available from literature to evaluate the accuracy and reliability of our simulations. Subsequently, the validated numerical technique is applied to the V-bending process with groove, which primarily aims to reduce bending radius. The influence of adding grooves in the V-bending process was examined to assess its effects on bending radius and springback angle. Numerical results from V-bending simulations with grooves indicate promising control over springback, thereby enhancing quality of final product. The effects of sheet thickness and groove depth were also analyzed, revealing that greater groove depth increases the springback angle and reduces the initial bending radius. Furthermore, increased sheet thickness was observed to slightly increase the radius after springback, emphasizing the role of thickness in shaping bending behavior in V-groove processes.