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Volume 18
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10.3390/ma18030608
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Article

Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer

by
Naotaka Nakamura
1,*,
Yuri Hata
2,
Witthaya Daodon
3,
Daiki Ikeda
2,
Nozomu Adachi
2,
Yoshikazu Todaka
2 and
Yohei Abe
2,*
1
Department of Engineering, National Institute of Technology (KOSEN), Nagano College, 716 Tokuma, Nagano 381-8550, Japan
2
Department of Mechanical Engineering, Toyohashi University of Technology, 1-1 Hibarigaoka, Tempaku, Toyohashi 441-8580, Japan
3
Department of Industrial Engineering, Faculty of Engineering and Technology, Rajamangala University of Technology Isan, Nakhon Ratchasima 30000, Thailand
*
Authors to whom correspondence should be addressed.
Materials 2025, 18(3), 608; https://doi.org/10.3390/ma18030608
Submission received: 27 December 2024 / Revised: 23 January 2025 / Accepted: 24 January 2025 / Published: 29 January 2025
(This article belongs to the Special Issue State of the Art in Materials for Additive Manufacturing)
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Highlights

  • The strain distributions on sidewall surfaces of a 3D-printed PLA punch and die in V-bending were calculated by means of a digital image correlation (DIC) method.
  • The reduced bending load due to a long span resulted in smaller deformation of the punch and die.
  • The DIC method enabled the observation of a characteristic strain distribution in a bending process with bottoming.

Abstract

In the V-bending of sheet metals using a pair of plastic punch and die manufactured by a 3D printer, the effects of two different dimensions designed with the same tool geometry on the deformation behaviors of the punch, die, and sheet were evaluated. The deformation behavior and strain distribution of the punch, die, and sheet were analyzed using a digital image correlation method. Sheets from pure aluminum to ultra-high-strength steel were bent using the two tools with different spans; one was designed on the assumption of tool steel material, and the other was designed on the assumption of plastic material. In both tools, the large compressive strain appeared around the center of the punch tip and on the corners of the die. The tools with a long span for the plastic material gave a lower bending force and small deformation of the plastic tools. The angle difference between a bent sheet at the bottom dead center and a tool was smaller for the tools with the long span, although the springback in the bent sheet appeared. It was found that the design method on the assumption of the plastic material is effective for the V-bending plastic tools.
Keywords: fused deposition modeling; tool design; deformation behavior; strain distribution; springback fused deposition modeling; tool design; deformation behavior; strain distribution; springback
Graphical Abstract

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MDPI and ACS Style

Nakamura, N.; Hata, Y.; Daodon, W.; Ikeda, D.; Adachi, N.; Todaka, Y.; Abe, Y. Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer. Materials 2025, 18, 608. https://doi.org/10.3390/ma18030608

AMA Style

Nakamura N, Hata Y, Daodon W, Ikeda D, Adachi N, Todaka Y, Abe Y. Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer. Materials. 2025; 18(3):608. https://doi.org/10.3390/ma18030608

Chicago/Turabian Style

Nakamura, Naotaka, Yuri Hata, Witthaya Daodon, Daiki Ikeda, Nozomu Adachi, Yoshikazu Todaka, and Yohei Abe. 2025. "Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer" Materials 18, no. 3: 608. https://doi.org/10.3390/ma18030608

APA Style

Nakamura, N., Hata, Y., Daodon, W., Ikeda, D., Adachi, N., Todaka, Y., & Abe, Y. (2025). Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer. Materials, 18(3), 608. https://doi.org/10.3390/ma18030608

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