Related Experiment Video
Updated: Aug 14, 2026
07:36
Experimental Procedure for Warm Spinning of Cast Aluminum Components
Published on: February 1, 2017
Springback Behavior and Stroke-Based Compensation Strategy for Roll-Based Bending of High-Strength Aluminum
Jeongsik Lim1,2, Hyungjun Kim2, Jinho Kim2
1Gyeongbuk Technopark, 120 Gongdan 7-ro, Jillyang-eup, Gyeongsan 38463, Republic of Korea.
Materials (Basel, Switzerland)
|August 13, 2026
Summary
Feeding displacement is the primary factor influencing springback in high-strength aluminum tubular extrusions during roll bending. A simulation-based compensation method was developed to achieve target curvatures accurately.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Lightweight automotive structures increasingly utilize high-strength aluminum tubular extrusions.
- Springback in bending compromises geometric accuracy, necessitating compensation strategies.
- Roll-based bending processes involve multiple parameters affecting springback behavior.
Purpose of the Study:
- To investigate the springback behavior of high-strength aluminum tubular extrusions during roll-based bending.
- To comparatively evaluate the effects of feeding displacement, roller speed, and internal mandrel application.
- To develop a simulation-based springback compensation approach for accurate geometric control.
Main Methods:
- Finite-element analysis (FEA) was employed to simulate the roll-based bending process.
- Springback was quantitatively assessed by measuring displacement and angular deviation post-unloading.
- The influence of feeding displacement, roller rotational speed, and internal mandrel application was systematically analyzed.
Main Results:
- Roller rotational speed showed a negligible effect on springback.
- Feeding displacement was identified as the dominant factor governing springback.
- Internal mandrel application reduced stress and wrinkles but did not alter the dependency on feeding displacement.
Conclusions:
- Feeding displacement is the critical parameter for controlling springback in this application.
- A simulation-based stroke compensation strategy can effectively achieve desired curvatures.
- A compensation window for a target radius of 150 mm was numerically identified.
Related Concept Videos
01:23Design of Prismatic Beams for Bending
The design of prismatic beams, structural elements with a uniform cross-section, focuses on ensuring safety and structural integrity under load. The design process begins by determining the allowable stress, either from material properties tables, or by dividing the material's ultimate strength by a safety factor. This safety factor is essential for accommodating uncertainties, and varies depending on the material—timber, steel, or concrete—with each having unique strength and stress...
01:10Bending
Pure bending is a fundamental concept in structural mechanics, essential for understanding how materials deform under symmetrical loads without direct forces. Pure bending occurs when prismatic members, such as beams, are subjected to equal and opposite moments that induce bending. The phenomenon is crucial as it allows for predicting stress distributions without the influence of axial or shear forces.
In pure bending, the bending stress in a beam is calculated based on the bending moment and...
In pure bending, the bending stress in a beam is calculated based on the bending moment and...
01:18Residual Stresses in Bending
In the study of elastoplastic members subjected to bending moments, understanding the loading and unloading phases is crucial for assessing material behavior and structural integrity. During the loading phase, as the bending moment increases, the material initially responds elastically, adhering to Hooke's Law, where stress is directly proportional to strain. When the load exceeds the yield strength, plastic deformation occurs, resulting in permanent strain and deformation that remains even...
01:14Plastic Deformations
It is essential to understand how structural members behave under plastic deformation when the bending stress exceeds the material's yield strength. This state of deformation permanently alters the shape of the member, in contrast to the linear elastic behavior observed before yielding. The strain at any point in the member is expressed in terms of maximum strain. Notably, the neutral axis, which coincides with the centroid during elastic bending, shifts away from the centroid under plastic...
01:19Plastic Deformations
Plastic deformation represents a fundamental concept in materials science, which explains the irreversible change in the shape of a material when it experiences stress beyond its elastic capability. This phenomenon is important in structural engineering, especially in designing and analyzing cantilever beams—structures that are securely fixed at one end and bear loads at the opposite end. When these beams are subjected to loads within their elastic range, they will return to their original...
01:18Unsymmetric Bending
Unsymmetrical bending occurs when the bending moment applied to a structural member does not align with its principal axis. This misalignment leads to complex stress distributions and deflection patterns that differ from those in symmetrical bending, and are essential for designing structures to withstand different loading conditions. In unsymmetrical bending, the neutral axis—where stress is zero—does not necessarily align with the geometric axes of the cross-section. The orientation of the...