Finite element analysis of a taper U-shape in the U-bending process

摘要

>A taper U-channel part is a commonly produced type of geometrically complex U-channel shape. However, there is a lack of research on the bending process of taper U-channel parts, which has resulted in difficulty controlling the spring-back characteristics. Therefore, in this study, the bending mechanism of a taper U-channel part was clearly identified and compared with that of a flat U-channel part, using the finite element method (FEM). The effects of the process parameters, including punch radius, taper angle, and channel width, on the spring-back characteristics were also investigated. The taper of the U-channel shape resulted in changes to the workpiece placement underneath the punch, as well as in changes to the bending and reversed bending stress distributions in the bending allowance zone, the bottom surface, and in the legs of the workpiece. These features directly resulted in changes to the spring-back characteristics. The FEM simulations were validated with experimental tests. The FEM simulation results showed good agreement with the experiment results in terms of the bend angles and the bending forces.