Study of Coefficient of Friction and Springback Analysis of Brass in Bending at Elevated Temperature Conditions

In the present work, finite element analysis is carried out for the minimization of springback in the V-bending process for high-strength brass sheet metal. Firstly, the uniaxial tensile test is conducted to determine the various material properties required for finite element analysis. The various test parameters considered in the V-Bending process are temperature (573 K, 673 K and 773K), punch speeds (1 mm/min, 5 mm/min and 10 mm/min), holding time (30 s, 60 s and 90 s) and sheet orientation concerning rolling direction RD (00), ND (450) and TD (900) for finite element analysis. The bending under tension test is used to determine the coefficient of friction at different temperatures and lubrication conditions, and these values are implemented in finite element simulations of the V-bending process. Taguchi analysis is carried out to determine springback of high-strength brass alloy by selecting four control factors (temperature, punch speed, holding time, and orientation). From the analysis of the signal-to-noise (S/N) ratio, it is reported that the temperature (46.93%) is the most significant parameter which influences the springback followed by holding time (26.29%), sheet orientation (24.07%) and punch speed (2.69%). The optimal set obtained for the minimum springback of brass alloy and the conformation test is performed at the optimum set conditions (773 K temperature, 1 mm/min punch speed, 90 s holding time, and 90° to the rolling direction of a sheet). With the optimal set of process parameters, Springback decreased significantly to around 68.68%. Through the investigation of springback analysis, it is directly proportional to the temperature and holding time and inversely proportional to the punch speed, but sheet orientation doesn’t follow any trends.