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While the majority of industrial sheet bending processes consist of conventional air bending, more complex bending processes such as multi-point bending are also utilized. Multi-point bending involves forming several bends simultaneously with changing contact conditions. Of the various models that may be employed to simulate such processes, analytic models are most attractive for industrial applications as they are time-efficient, strongly theoretically supported and easily extended to a wide range of dies layouts without the need of additional experimental data. In this paper a new analytic model is presented to predict the forming forces, the deformation of the sheet and the springback. The model is based on the literature around large-radius air bending. The geometry of the sheet is determined at each moment as a function of the tool’s positions. The reaction forces are calculated based on the equilibrium of forces and moments and the springback is calculated based on the elastic unloading of the internal bending forces. The model has been compared with a more time consuming finite element (FE) model and the geometry of the sheet has been experimentally verified by means of digital processing of video images. The proposed analytic model shows good agreement with the computational FE model and it is demonstrated to be a robust tool for calculation of the bending characteristics.

Analytic Model for Multi-point Large-Radius Bending of Steel Sheets