Experimental and Numerical Investigation of Folding Process—Prediction of Folding Force and Springback

The folding process is characterized by the springback phenomenon. Several experimental folding tests are elaborated and illustrated in this paper. The precision and the quality of the folded sheet workpiece are related to the reduction in the springback phenomena. For that, two tools are designed and used for the folding process. An accurate design of the folding tool plays a significant role in contributing to the folding process and reducing potential defects related to springback. An experimental solution is presented to avoid the forming of defaults and compensate the workpiece springback after its removal from the die. Moreover, an accurate numerical modeling enables an efficient prediction of the springback. This allows us to obtain precise parts through the folding process. For that, a modified Johnson–Cook model is implemented on ABAQUS software in order to predict the folding force and the springback in a U-die folding process. In addition to the isotropic hardening law, a nonlinear kinematic hardening rule is used. To ensure the model’s accuracy and reliability, we conducted validation experiments. The model’s predictions are compared with experimental tests to show its capability to simulate the folding process effectively. The developed mechanical model can adequately predict and analyze springback effects and folding force evolution, helping designers compensate for them and achieve the desired final shape.