Parametric Study on the Spring-Back Effect in AA5052 Alloy in the Course of Three-Point Roll Bending Process

Three-point roll bending is one of the most common forming processes employed to obtain the desired radius of curvature in the sheet metal operations. Upon the removal of the forming load, the sheet metal deforms to a lesser extent than that of the required dimension. This phenomenon is termed as spring-back and is considered the most challenging areas of research in three-point roll bending of sheet metals. This study aims to develop a numerical model using HyperWorks and Radioss solver to understand the influence of load, the distance between the forming rollers, and its thickness on the spring-back effect in the course of three-point roll bending of sheet metal (AA5052). The results of the numerical model are validated with the results of the experimental trials. Besides, a statistical model is developed to relate the amount of spring-back with the three-point roll bending process parameters.