Bending is a common sheet metal forming operations in the manufacturing industry, specifically in the HVAC manufacturing sector addressed in this thesis. Bending is a
process of plastic deformation of sheet metal around an axis, resulting in a change of its shape. During bending, the sheet metal undergoes two types of deformation: tensile
deformation occurs on the convex side, while compressive deformation appears on the concave side. Between the tensile and compressive stress regions lies the neutral plane,
where no deformation occurs.
The position of the neutral plane is not located at the middle of the sheet thickness, but it depends on the material, sheet thickness, bending radius, bending angle, bending method, and other process parameters. This position is described by the K-factor, which is essential for calculating the developed (flat) length of the sheet metal, as it enables accurate determination of dimensions and precise manufacturing of HVAC structural components.
In the experimental part, the K-factor was determined based on measurements, after which numerical simulations were used to verify whether the K-factor could also be accurately predicted through simulation. A tensile test was performed to determine the mechanical properties of the sheet metal. The K-factor was calculated from the
dimensions and data measured on bent samples in the company and subsequently verified using the engineering simulation software ANSYS.
A table of K-factors was developed to serve as a reference tool for design engineers and
technologists in accurately determining the developed (flat) length of sheet metal for specific materials and bending conditions.
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