Effect of material discontinuity on springback in sheet metal bending

Origami-based sheet metal, a novel emerging technique, is explored in this paper. The process is similar to traditional process of making the Origami art from paper. Sheet metal forming is also considered as a paper with negligible thickness. Here the process was tried differently than traditional sheet metal-bending process. On the bend line, the material was removed intermittently. This process created the material discontinuity at the bend line. However, removing the material from the bend line opened the sections and it would not be able to use as a container to hold any liquid material due to leakage issue. Thus, in this paper, the material discontinuity was created by removing the small amount of material but not through. This can be called as blind material discontinuity. With change in thickness and width at material discontinuity four samples were created to see the effect on bending deformation and springback. In addition, die clearances and either MD will be faced on die or punch side was explored. From the results it was found that the lower thickness at material discontinuity and on die side would provide lower springback if the width of material discontinuity is higher.