JeetBhuva Project Description

Project introduction – Jeet Bhuva


Main aim of the project is to understand the deformation characteristics in a novel sheet metal forming process wherein an initially curved sheet is flange-drawn over the die radius with a curved bend axis.


By virtue of the classical theory of folded developables, a concave and a convex cylindrical developable surface can be connected by a curved fold line. However, the theory was developed for mathematical 2D surfaces folding over a zero-radius fold line. When applying this theory to corrugated sheet metal, thickness of the sheet and the associated non-zero bend radius cannot be ignored. Geometrical and mechanical effects of these unavoidable parameters lead to part defects like curving, coning and spread-out of the deformed leg. Thus, an in-dept study is required to capture the deformation characteristics in the process, develop an analytical model suitable for the process and finally, check the influence of various material and process parameters on deformation in order to mitigate or eliminate part defects.


Research methodology is mainly divided in three sections. Firstly, to analyse deformation characteristics of the process, forming trials with varying material grades and number of corrugations are performed. Corrugated profiles are 3D scanned at each step of the process and analysed to gauge the change in shape of the profile after forming. Change in shape of the profile from FE simulation of the process will be validated using the experimental results. Analysis of stress-strain distribution from the FE model will help deduce the deformation characteristics of the process. For analytical modelling, the theory of folded developables is extrapolated to consider the geometrical effects of non-zero bend radius and finite sheet thickness. Next, existing analytical models of contour flanging and flange drawing will be combined to consider mechanics of the process. A validated analytical model shall point out the factors influencing deformation and in-turn, part defects. Numerical simulation will be used to check the improvement in part quality by modifying relevant process parameters.

Future work:

  • FE simulation of curving
  • Analytical model embedding mechanics of the process
  • Link factor influencing deformation to part defects


Jeet Bhuva

Institute for Frontier Materials (IFM)

Deakin University, Geelong

Email: [email protected]