Design and Construction of Adjustable V-bending Die for Thin Metal Sheets

Abstract

V-shaped profiles are commonly found in sheet metal bending applications. The selection of an appropriate bending die is essential for producing workpieces under various forming conditions, including material type, sheet thickness, and tool geometry. In this study, an adjustable V-bending die for a three-point bending process was designed and developed to enhance forming flexibility. The tool components were designed to be interchangeable, allowing different configurations to be tested. Finite Element Modeling: FEM was employed to investigate the effects of key tool geometrical parameters, including Punch Radius: Rp, Die Radius: Rd, and Die Opening: W. The results indicated that the bending angle was strongly dependent on the punch stroke. Sensitivity analysis revealed that sharper bending angles were achieved with increased punch stroke and larger tool radii, while a smaller die opening resulted in greater bending deformation. Structural analysis of the die components manufactured from AISI 1045 steel confirmed that both the punch insert and die insert possessed sufficient strength to withstand the applied forming loads without undergoing plastic deformation. Experimental validation demonstrated that the deviation between the simulated and measured bending angles was less than 3%, confirming the accuracy and reliability of the developed die. Furthermore, the developed tool was applied to investigate the springback behavior of AA1100 aluminum alloy and AISI 1005 steel. Specimens were tested at target bending angles of 80°, 90°, and 100°, and springback compensation was successfully achieved by increasing the punch stroke.