Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

@article{200032,
        author = {Nikhil Mankar},
        title = {Energy-Based Evaluation of Springback Behaviour in Sheet Metal Bending Using Finite Element Modelling and Statistical Optimization},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {12},
        pages = {356-361},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=200032},
        abstract = {Accurate estimation of springback in sheet metal bending remains a persistent challenge in manufacturing industries, primarily due to the combined influence of material behaviour, tooling configuration, and process parameters. Conventional approaches largely rely on stress–strain analysis, which, although useful, does not directly represent the fundamental mechanism governing elastic recovery after unloading. In the present study, an energy-oriented approach is introduced to provide a clearer understanding of springback behaviour. A three-dimensional finite element model representing a punch die sheet assembly was developed and analysed using an explicit dynamic formulation to simulate the V-bending process. Three materials Copper, Aluminum 1100, and Aluminum 5083 were examined under identical loading and boundary conditions to evaluate their comparative responses. Unlike traditional methods, this investigation focuses on the evolution of internal energy as a primary indicator of elastic recovery. Internal energy, which reflects the work absorbed and stored within the material during deformation, is directly associated with the extent of springback. In addition, key geometric parameters such as die angle and die length were systematically varied and optimized using Taguchi design of experiments coupled with response surface methodology. The results demonstrate a clear relationship between internal energy accumulation and springback behaviour. Materials with higher energy storage exhibited a greater tendency to recover elastically after unloading. Among the materials studied, copper showed the highest internal energy levels, indicating a stronger springback effect, while aluminum alloys exhibited comparatively lower energy accumulation. The proposed framework offers a more physically meaningful and efficient approach for analyzing and controlling springback in sheet metal forming processes.},
        keywords = {Springback behaviour, Sheet metal forming, Energy-based analysis, Finite element modelling, Process parameter optimization, Taguchi method},
        month = {May},
        }