Experimentation and Numerical Modeling of Forging Induced Bending (FIB) Process

Accurate prediction of the final shape using numerical modeling has been a top priority in the field of sheet and bulk forming. Better shape prediction is the result of a better estimation of the physical stress and strain state. For experimental and numerical investigations of such estimations, simple benchmark processes are used. In this paper a benchmark process involving forging (flattening) of sheet metal between punch and die with negative clearance is proposed. The introduced material flow results in bending. Easy measurability of the angle of this bend makes this process suitable for validation purpose. Physical experiments are performed to characterize this bending angle due to flattening. Furthermore a numerical model is developed to capture this phenomenon. The main focus of this paper is the validation of the numerical model in terms of accurate prediction of the physical results.