Research Papers

Finite Element Analysis of Origami-Based Sheet Metal Folding Process

[+] Author and Article Information
Muhammad Ali Ablat

Department of Mechanical Engineering,
University of California, Merced,
Merced, CA 95343
e-mail: amaimaitiaili@ucmerced.edu

Ala Qattawi

Department of Mechanical Engineering,
University of California, Merced,
Merced, CA 95343
e-mail: aqattawi@ucmerced.edu

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received September 15, 2017; final manuscript received January 19, 2018; published online April 6, 2018. Assoc. Editor: Huiling Duan.

J. Eng. Mater. Technol 140(3), 031008 (Apr 06, 2018) (7 pages) Paper No: MATS-17-1269; doi: 10.1115/1.4039505 History: Received September 15, 2017; Revised January 19, 2018

Origami-based sheet metal (OSM) folding is a novel approach regarded as extension of the origami technique to sheet metal. It requires creating numerous features along the bend line, called material discontinuities (MD). Material discontinuities control the material deformation and result in reduced bending force (BF), minimal tooling, and machinery requirements. Despite the promising potential of OSM, there is little understating of the effect of the selected MD shape and geometry on the final workpiece. Specifically, this is of interest when comparing the manufacturing energy and cost allocations for OSM with a well-establish process for sheet metal such as stamping. In this work, wiping die bending of aluminum sheet with different MD shapes and geometries along the bend line is investigated using finite element analysis (FEA) and compared to traditional sheet bending in terms of stress distribution along the bending line, required bending force and springback. The FEA results are validated by comparing it to the available empirical models in terms of bending forces. This study found that OSM technique reduced the required bending force significantly, which has important significance in energy and cost reduction. The study also found each MD resulted with different bending force and localized stress. Hence, MD are ranked in terms of the required force to bend the same sheet metal type and thickness for further future investigation. Springback is decreased due to application of MD. Meanwhile, MD generated localized high stress regions along the bending line, which may affect load-bearing capability of the final part.

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Fig. 1

An example of floor panel of aluminum sheet produced with OSM technique, shown part was folded manually from a single flat pattern with minimal tooling [12,13]

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Fig. 2

Various possible MD designs for OSM technique. Either laser cutting or stamping processes can be used to create them.

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Fig. 3

The selected MD shapes for the FEA study presented in this work, the assigned number for each shape is for distinguishing purpose. All of the MD are laser cut and the same length of material is left along bend line after removal of material for comparison purpose: (a) MD-14, (b) MD-33, (c) MD-243, and (d) MD-433.

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Fig. 4

Wiping die bending configuration

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Fig. 5

Meshing illustration: (a) meshing of MD-14, top view and (b) MD-14 five mesh layers in thickness direction

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Fig. 6

Mesh convergence studies result: (a) without MD, (b) MD-14, (c) MD-33, (d) MD-243, and (e) MD-433

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Fig. 7

Bending force versus punch displacement plot for each of the studied MD cases and the traditional sheet metal case with no MD along the bend line

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Fig. 8

Von Mises stress distribution for each MD case under study: (a) without MD, (b) MD-14, (c) MD-33, (d) MD-243, and (e) MD-433



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