A NUMERICAL STUDY ON EFFECT OF TOOL ROLLER ROTATION ON CHANNEL SPRINGBACK

The current work is an extension of the work published at IMECE2020. The study presents the innovative patented technique to reduce the springback in channel deformation. Springback is one of the common defects in sheet metal forming and is a constant research area due to continuous push on lightweight to decrease the fuel consumption and decrease the environmental impact. To follow the federal environmental guidelines the option is either use the lower density material or use the lower gages of advance high strength materials. In both cases springback will be an issue as the lower density material will be having lower modulus of elasticity and even the elastic values are higher in the higher strength material, with respect to strength the elastic recovery increases. With these many challenges with the materials and their properties which influences the springback, other possible innovative forming processes are applying electricity through the material after forming and before the release of the load, performing warm or hot forming, die compensation, etc. One such innovative and patented process which is studied in the paper is using rollers in the tool i.e., in die and punch during the forming process. During the channel deformation process the punch and die rollers rotate with a given rotations. The rollers are also set to rotate in either clockwise or counterclockwise direction. In IMECE2020 the work was published on considering the single roller rotation value in all cases i.e., from Case3 to 10. In this paper, four more roller rotations were studied to see the effect of tool roller rotation on the springback. The process was simulated in ABAQUS finite element software. The springback profile, springback angle and stresses in the channel were studied. It was found that with increasing the roller rotations the springback decreases.