Finite element method–based multi-objective optimization of press-brake bending of sheet metal

Perforated metals have many positive attributes, both aesthetic and practical, that make them a suitable material for many applications. Perforation of metals is the process of removal of materials from the sheet metal in different geometries, ornamental forms, or the punching/stamping of holes into metal sheets for practical or aesthetic reasons. This operation is based on different parameters such as the type of material, thickness of material, and open area, which can affect operations such as bending. This research paper focuses on the parametric multi-objective optimization of the press-brake bending process of perforated aluminum alloy, as well as the optimization of the impact of different parameters such as bend angle and blank variables (thickness and pitch perforation) on the springback of perforated aluminum alloys, and also investigates which variable can achieve the best product quality. Aluminum alloy (AA1300) thicknesses of 0.50, 1.00, and 1.50 mm were investigated in this study. The bend angles used are 60°, 90°, and 120°, whereas the blank parameters are plain, square perforated, circular, and staggered perforated. Bending was performed using the finite element method (FEM) tool Abaqus software. Afterward, the springback result of bending was optimized using the multi-objective optimization method. In the 60° bending angle, the perforation has a greater impact on the springback than in the 90° bending angle, and the 90° bending angle has a greater impact than the 120° bending angle. The springback of circular perforated sheet metal is roughly equal to that of the plain sheet metal. The springback of the square perforated sheet AA is nearly equal to that of the plain and other types of perforated aluminum alloys.