Behavior and Analysis of Stainless Steel Wires Under Straight Bending

Abstract

The study aimed to establish effective tools and methodologies for optimizing the bending process of metal wires, particularly focusing on the performance of SUS304 stainless steel in manufacturing torsion springs. This includes addressing challenges like spring-back and ensuring product quality and lifespan. The research employed a combination of analytical approaches, computer simulations using the Finite Element Method (FEM), and mechanical tests to validate the bending process. The mathematical analysis provided a theoretical framework, while FEA simulations allowed for the assessment of stress distribution and strain during bending. The simulations indicated that strains were distributed over a larger fiber than initially assumed, allowing for smaller bending radii without compromising material integrity. Using analytical models and supported by FEM, the study identified an effective range of bending radius values based on mechanical properties and wire radius. Laboratory tests confirmed that the bending process can be executed effectively, with no defects observed in the wire bending. Experimental tests validated these findings, showing consistent improvement in the accuracy, structural integrity, and durability of the formed wires. These results provide practical guidance for manufacturers seeking enhanced product quality and performance.