Spring back in sheet metal bending

All metal has a certain degree of spring back after its being bent. During sheet metal bending, the
interior radius of the bent metal is under compression and the exterior bend radius is in tension and
stretched. Due to the metals’ elasticity, it tends to go back to its original shape after its being bent and
this is know as spring back. All metals, when subjected to deformation, exhibit a certain amount of
elastic recovery.

Factors affecting spring back in sheet metal bending.

1. The greater the yield strength of the material, the greater the spring back will be.
2. The thinner the raw material, the greater the spring back.

Overcoming spring back in progressive tool

I tried many methods in the past. Such as coining the external bend radius, over bend the angle,
reduce bending clearance etc. All these can’t really provide an effective solution to it until I tried
the following method which I’m happily using for almost all the high speed progressive tools in
my design.

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recylization temperature

forging processes can be performed at various temperatures, however they are generally
classified by whether the metal temperature is above or below the recrystallization temperature.
If the temperature is above the material's recrystallization temperature it is deemed hot forging; if
the temperature is below the material's recrystallization temperature but above 3/10ths of the
recrystallization temperature (on an absolute scale) it is deemed warm forging; if below 3/10ths
of the recrystallization temperature (usually room temperature) then it is deemed cold forging.
The main advantage of hot forging is that as the metal is deformed work hardening effects are
negated by the recrystallization process. Cold forging typically results in work hardening of the
piece.

Hot working
Hot working refers to processes where metals are plastically deformed above their
recrystallization temperature. Being above the recrystallization temperature allows the material
to recrystallize during deformation. This is important because recrystallization keeps the
materials from strain hardening, which ultimately keeps the yield strength and hardness low
and ductility high

Advantages & disadvantages

The advantages are:

 Decrease in yield strength, therefore it is easier to work and uses less energy or force
 Increase in ductility
 Elevated temperatures increase diffusion which can remove or reduce chemical
inhomogeneities

The disadvantages are:

 Undesirable reactions between the metal and the surrounding atmosphere (scaling or
rapid oxidation of the workpiece)
 Less precise tolerances due to thermal contraction and warping from uneven cooling
 Grain structure may vary throughout the metal for various reasons

Cold working
also known as strain hardening, is the strengthening of a metal by plastic deformation. This
strengthening occurs because of dislocation movements within the crystal structure of the
material Any material with a reasonably high melting point such as metals and alloys can be
strengthened in this fashion Alloys not amenable to heat treatment, including low-carbon steel,
are often work-hardened. Some materials cannot be work-hardened at normal ambient
temperatures, such as indium however others can only be strengthened via work hardening,
such as pure copper and aluminum

Advantages and disadvantages

Advantages:

 No heating required
 Better surface finish
  Superior dimensional control

Disadvantages:

 Greater forces are required

 Heavier and more powerful equipment and stronger tooling are required
 Metal is less ductile
 Metal surfaces must be clean and scale-free

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Upset forging
Upset forging increases the diameter of the workpiece by compressing its length. Based on
number of pieces produced this is the most widely used forging process A few examples of
common parts produced using the upset forging process are engine valves, couplings, bolts,
screws, and other fasteners.

Upset forging is usually done in special high speed machines called crank presses, but upsetting
can also be done in a vertical crank press or a hydraulic press. The machines are usually set up to
work in the horizontal plane, to facilitate the quick exchange of workpieces from one station to
the next. The initial workpiece is usually wire or rod, but some machines can accept bars up to
25 cm (9.8 in) in diameter and a capacity of over 1000 tons. The standard upsetting machine
employs split dies that contain multiple cavities. The dies open enough to allow the workpiece to
move from one cavity to the next; the dies then close and the heading tool, or ram, then moves
longitudinally against the bar, upsetting it into the cavity. If all of the cavities are utilized on
every cycle then a finished part will be produced with every cycle, which is why this process is
ideal for mass production

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The references :

 www.Wikipedia.com
 www.wisetoolblog.com