The Optimization of Rotary Bending Die Process: Criteria for the Metal Sheet Angles and Springback Effects

Abstract

Rotary die bending enables the precise fabrication of sheet metal components across various bending angles, offering high dimensional accuracy, structural stability, and reduced springback. This study employs explicit and implicit numerical simulations using the Abaqus software to analyze the rotary die bending process and springback behavior of SUS304 stainless steel sheets. Five key criteria are investigated: desired angle post-springback (αsi), springback factor (ksi), forming stress (Von Mises) at the required bending angle (Sr), residual stress (Von Mises) after springback (Sb), and equivalent plastic strain (PEEQ). These criteria enable accurate predictions of material behavior during rotary die bending, including elastic-plastic deformation and stress distribution. The insights gained support a more flexible design process, enhance the precision of sheet metal bending, and ensure that the final product meets the specified requirements. This research serves as a valuable reference for professionals working with sheet metal components made from various metals and bimetal sheets. Additionally, it informs strategies to mitigate or eliminate residual stress in bent parts, improving reliability and manufacturability.