When the sheet is bent, the stress distribution in the cross section with consideration of the initial stress is shown in Fig. 1. In this paper, the residual stress is taken into consideration in the theoretical analysis of the workpiece bending. The cross section can be divided into three regions, i.e., the superposition areas in upper and lower surfaces and remaining area. Therefore, the stress distribution in the superposition areas inherits the bending stress and the milling-induced stress.
The following assumptions are listed to build the springback prediction model for sheet bending:
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The volume of the material is constant during the bending process, which can be written as \({\varepsilon _\theta }+{\varepsilon _b}+{\varepsilon _r}=0\), where \({\varepsilon _\theta }\), \({\varepsilon _b}\), \({\varepsilon _r}\) represent the strain components in the direction of tangential, radial, and thickness.
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The plane strain condition, \({\varepsilon _b}\)= 0, is adopted during press-braking bending for wide plate.
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The contact region between punch and sheet is assumed to be circular [37], and the neutral surface always stay at the same position.
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The material exhibits Swift exponent-hardening behavior, which satisfy the stress-strain law: \(\overline {\sigma } {\text{=}}K{\left( {{\varepsilon _0}+\overline {\varepsilon } } \right)^n}\)[38, 39], where \({\varepsilon _0}\) is material parameters given by \({\sigma _0}{\text{=}}K{\varepsilon _0}^{n}\), is strength coefficient, andis hardening exponent.
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The shear stress is ignored during bending, and the arbitrary cross-section remains plane and perpendicular to the deformed middle surface of the sheet [40].
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Von Mises criterion, which is suitable for the ductile materials, is used for plastic yielding,.
Due to the milling operation, the surface material inherits the bending stress and the milling-induced stress. The stress on the bent plate cross-section with consideration of surface residual stresses can be expressed as follows:
$${\sigma _\theta }^{\prime }={\sigma _\theta }+{\sigma _{mill}},\;\;\;{\rho _i}\, \leqslant \rho \leqslant {\rho _o}$$
1
where \({\sigma _\theta }\) is the tangential stress during bending process without consideration of the milling-induced stress and distributes in the range of \(\left[ {{{ - t} \mathord{\left/ {\vphantom {{ - t} 2}} \right. \kern-0pt} 2},{t \mathord{\left/ {\vphantom {t 2}} \right. \kern-0pt} 2}} \right]\), which have been derived in our former study [41]:
For the elastic deformation zone
$$\begin{gathered} {\sigma _\theta }=\frac{E}{{1{\text{-}}{\nu ^2}}}\ln \frac{\rho }{{{\rho _n}}}+\frac{{\nu E}}{{\left( {1 - {\nu ^2}} \right)\left( {1 - 2\nu } \right)}}\frac{{{y_e}}}{{{\rho _n}}} - \frac{\nu }{{1 - 2\nu }}\frac{2}{{\sqrt 3 }}K{\left( {{\varepsilon _0}+\frac{2}{{\sqrt 3 }}\ln \frac{{{\rho _n}+{y_e}}}{{{\rho _n}}}} \right)^n}\;\; \hfill \\ \;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;({\rho _n} - {y_e}<\rho <{\rho _n}+{y_e}) \hfill \\ \end{gathered}$$
2
and
$${\sigma _\theta }=\left\{ \begin{gathered} {\sigma _r} - \frac{2}{{\sqrt 3 }}K{\left( {{\varepsilon _0} - \frac{2}{{\sqrt 3 }}{\varepsilon _\theta }} \right)^n}{\text{ }}{\rho _\text{i}} \leqslant \rho \leqslant {\rho _\text{n}} - {y_\text{e}} \hfill \\ {\sigma _r}+\frac{2}{{\sqrt 3 }}K{\left( {{\varepsilon _0}+\frac{2}{{\sqrt 3 }}{\varepsilon _\theta }} \right)^n}{\text{ }}{\rho _\text{n}}+{y_\text{e}} \leqslant \rho \leqslant {\rho _\text{o}} \hfill \\ \end{gathered} \right.$$
3
where E is Young’s modulus, and ν refers to the Poisson ratio. ρ is the curvature radius of the measured point. ρn is the curvature radii of the neutral layer before unloading. ye is half the thickness of elastic deformation. σr is stress in the radial direction. K is strength coefficient. n is hardening exponent. ε0 is material parameter. εθ is the strain component in the tangential direction. ρi and ρo are the curvature radii of the innermost and outermost surfaces of the bent plate, respectively.
The milling-induced stress \({\sigma _{mill}}\) can be expressed as below,
$${\sigma _{mill}}=\left\{ {\begin{array}{*{20}{l}} {\sigma _{{res}}^{{surf}},\;\;\;{{ - t} \mathord{\left/ {\vphantom {{ - t} 2}} \right. \kern-0pt} 2}\, \leqslant t \leqslant {{ - t} \mathord{\left/ {\vphantom {{ - t} 2}} \right. \kern-0pt} 2}\,+{t_r},{t \mathord{\left/ {\vphantom {t 2}} \right. \kern-0pt} 2}\, - {t_r} \leqslant t \leqslant {t \mathord{\left/ {\vphantom {t 2}} \right. \kern-0pt} 2}\,} \\ {0,\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;\;{{ - t} \mathord{\left/ {\vphantom {{ - t} 2}} \right. \kern-0pt} 2}\,+{t_r} \leqslant \rho \leqslant {t \mathord{\left/ {\vphantom {t 2}} \right. \kern-0pt} 2}\, - {t_r}} \end{array}} \right.$$
4
where \({t_r}\) is the thickness of surface stress in Fig. 2, \(\sigma _{{res}}^{{surf}}\)is the surface residual stress induced by milling operation.
The total cross-section stress is the superposition of bending stress and initial stress. The bending moment is defined below,
$$M{\text{=}}\omega \int {\begin{array}{*{20}{c}} {{\rho _o}} \\ {{\rho _i}} \end{array}} {\sigma _\theta }^{\prime }\left( {\rho - {\rho _n}} \right)d\rho$$
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where \(\omega\) is width of the cross section.
The elastoplastic curvature change is equal to the elastic curvature change caused by the bending moment based on the classical springback theory, i.e., the springback bending moment and bending moment are equal in quantity and opposite in direction. The curvature change after the springback is achieved below [42, 43],
$$\Delta K=\frac{1}{{{\rho _0}}}{\text{-}}\frac{1}{{{\rho _1}}}{\text{=}}\frac{M}{{EI}}$$
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with \(I{\text{=}}{{\omega {t^3}} \mathord{\left/ {\vphantom {{\omega {t^3}} {12}}} \right. \kern-0pt} {12}}\), where is the moment of inertia of the cross section, \(\Delta K\) is the springback curvature, \({\rho _0}\) and \({\rho _1}\) are bending radius of the neutral layer before and after unloading.
According to the length of neutral layer remains the same,\({\rho _1}{\alpha _1}{\text{=}}{\rho _0}{\alpha _0}\), and with Eq. (18), the springback angle for the bent workpiece is obtained by:
$$\Delta \alpha ={\alpha _0}{\text{-}}{\alpha _1}{\text{=}}{\alpha _0}\left( {1{\text{-}}{\raise0.7ex\hbox{${{\rho _0}}$} \!\mathord{\left/ {\vphantom {{{\rho _0}} {{\rho _1}}}}\right.\kern-0pt}\!\lower0.7ex\hbox{${{\rho _1}}$}}} \right)$$
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where \(\Delta \alpha\) is springback angle, \({\alpha _0}\) and \({\alpha _1}\) are bending angle before and after unloading.
The detailed procedure used to solve for the springback curvature and springback angle is presented in Fig. 2. The effects of both the milling-induced stress and bending stress are considered in the SPM-RS model (springback prediction model with milling-induced stress). The milling-induced stress is not contained in the SPM-NRS model (springback prediction model without milling-induced stress) when the step 4 is ignored in the calculation flowchart.