Investigating the Influence of Drawbead Geometries on Springback Behavior in Aluminum Sheets during Metal Forming

Abstract

Springback is a critical challenge in sheet metal forming, leading to dimensional deviations and assembly difficulties in aluminium components. This study examines the effect of drawbead geometry on springback behaviour through finite element simulation of a 1 mm thick aluminium sheet subjected to punch–die bending. Four configurations are considered: a baseline case without drawbeads and three drawbead profiles (square, circular, and triangular), all evaluated under identical loading and boundary conditions using a static mechanical analysis framework. Springback is assessed by comparing characteristic bend angles before unloading and after elastic recovery, complemented by evaluation of maximum deformation, equivalent stress, and elastic strain fields. The results demonstrate that drawbeads substantially suppress springback, with the triangular drawbead providing the most pronounced improvement through localized stress concentration and reduced angular recovery.