An experimental and numerical study of deformation characteristics in flexible stretch bending using reconfigurable tools

Achieving high dimensional accuracy in metal forming processes is essential as this directly impacts product performance, functionality, and aesthetics. Understanding and controlling the factors that influence deformation behavior in metal forming, including springback and local distortions, can improve product integrity and the efficiency of forming and subsequent assembly operations. This study investigates local and global deformation characteristics of AA6082-T4 extrusions formed in stretch bending, using a novel multi-point reconfigurable die system. The experimental results are supplemented by finite element method (FEM) analysis to assess dimensional characteristics using three different die radii (R1000, R1500, and R1750 mm). The findings highlight the influence of discrete multi-point tool on overall deformation behavior after springback, including chord height de, during kinematically controlled bending and stretching. Furthermore, the results from this study serve to define the range of local deformation ensuring global deformation to remains within acceptable tolerance limits for formed products manufactured with reconfigurable multi-point tools.