Predicting springback in V-bending: Effects of load, load holding time, and heat treatment on common sheet-metal forming operations

Sheet metal forming, particularly V-bending, is essential in various industries; however, challenges such as springback can affect the precision and quality of the final component. This study explores the optimization of springback in V-bending by examining the effects of applied load, load holding time, and heat treatment on materials like aluminum (Al 5052), mild steel (AISI 1040), and stainless steel (AISI 304). Using Response Surface Methodology (RSM), the research systematically varies these parameters to identify optimal settings that minimize springback. Key findings include that increasing the applied load generally reduces springback for all materials, with stainless steel exhibiting the highest and aluminum the lowest springback. Longer load holding times help reduce springback by promoting stress relaxation, with aluminum showing the greatest reduction. Annealing significantly decreases springback by softening the material, while normalizing and quenching provide varying levels of reduction, particularly for steel. Notably, synergistic effects between applied load and holding time, as well as load and heat treatment, yield more effective springback reduction than when these factors are considered separately. The study highlights the need for tailored process parameters and heat treatment for each material. Future research should focus on exploring additional materials, heat treatments, machine learning applications, real-world validations, and advanced tooling to further enhance springback management.