Application of Mean Modulus in Three-Point Bending and Roll Forming

Nonlinear unloading plays an important role in predicting springback during plastic forming process. To improve the accuracy of springback prediction which could provide a guide for precision forming, uniaxial tensile tests and uniaxial loading–unloading–loading tensile tests on SUS304 stainless steel were carried out. The flow stress mathematical model and chord modulus mathematical model were calibrated according to the test results. A constant elastic modulus three-point bending finite element model ($E_{0}FEMB$) and a constant elastic modulus roll forming finite element model ($E_{0}FEMR$) were established in MSC.MARC. The chord modulus was output by the PLOTV subroutine to determine the mean modulus of different regions, and the mean modulus three-point bending finite element model (${\overline{E}}_{c}FEMB$) and the mean modulus roll forming finite element model (${\overline{E}}_{c}FEMR$) were defined. The constant modulus finite element model ($E_{0}FEM$) simulation results and the mean modulus finite element model (${\overline{E}}_{c}FEM$) simulation results were compared with the three-point bending tests and roll forming tests test results. The difference between the simulation results and the test results was small, indicating that the mean modulus was feasible to predict the springback, which verified the suitability of the ${\overline{E}}_{c}FEM$.