<p>The current demand in automotive vehicle usage results in sudden increases in fuel consumption, increasing air pollution. To avoid the environmental regulation penalty, the vehicle industry researches innovation, reduces vehicle weight, and decreases fuel consumption. However, the innovation related to light-weighting is not only an option anymore but became a mandatory necessity to decrease fuel consumption. To achieve this target, the industry has been looking at fabricating components from high strength to ultra-high strength steels or lightweight materials. With the usage of advanced high strength steels, the lightweight was achieved by reducing a gage thickness without compromising the strength aspect. However, due to their high strength property often challenges occurred are higher machine tonnage requirement, sudden fracture, geometric defect, etc. The geometric defect comes from the elastic recovery of a material, which is also known as a springback. Springback is commonly known as a manufacturing defect due to the geometric error in the part, which would not be able to fit in the assembly without secondary operation or compensation in the forming process. It is learned that the springback of the material increases with an increase in the material strength and/or decrease in material thickness. In advanced high strength steels, higher strength and lower gage thickness options make the part prone to higher springback. Due to these many challenges with the materials and their properties which affect the springback, other research routes involved are innovative forming processes which would reduce the springback such as 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. In this paper, the 2D channel strip of the bilayer material will be used in the bending process. The material used for bilayer will be aluminum 2024 high strength alloy and a composite fiber which will be joined to make a strip. The bending processes will be simulated in ABAQUS finite element software. The punch and die corner radii will be converted in the circular roller with same radius. These rollers will be set to rotate at a rotation during the process time. The direction of roller rotation i.e., clockwise or counterclockwise in both die and punch will also be studied. The metal layer or the composite layer will be set to face the punch side as well as the change in thickness of each layer will be changed to see the effect on the springback. Further the residual stress pattern in each layer, maximum stress, and resulting springback will be studied and presented.</p>

A Numerical Study on Effect of Tool Roller Rotation on Channel Springback

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

Supporting the need among researchers worldwide for additional online and multimedia content, ASME now offers the ASME Conference Video Collection. This platform will collect and provide long-term access to conference presentation videos, encompassing all technology areas within ASME's technical conference and events program. About 30,000-40,000 engineers across all mechanical engineering and related disciplines participate in ASME conferences each year. This includes authors of approximately 6,000 to 8,000 technical papers published by ASME, the majority of whom also submit video presentations for our virtual conferences. The video collection will be available as an add-on to existing product packages or as a separate subscription.