Simulation and experimental study of the V-bending process for SS304 and AA6061 sheets using additively manufactured tools

Purpose The purpose of this study is to explore the formability, dimensional precision, and cost-efficiency of acrylonitrile butadiene styrene (ABS) tooling as a feasible alternative to conventional methods. By integrating finite element analysis (FEA) simulations with experimental validation, the study provides insights into the performance and durability of ABS tools, offering an innovative solution for flexible and cost-effective manufacturing, particularly suited for small to medium-scale production. Design/methodology/approach This study investigates the use of 3D-printed tools in the V-bending process, using FEA and experimental setups at angles of 30°, 45° and 60°. The formability of 1 mm thick SS304 steel and AA6061 aluminum was evaluated, focusing on geometric precision, thinning and overall formability. Findings FEA results suggest that increasing sheet thickness may reduce formability for both materials. Simulations were compared with permissible limits to ensure accurate samples. Experimentally, 60 samples were bent using tools made from ABS. Research limitations/implications The limitations of this research include the use of specific material properties and process parameters, which may limit the generalized ability of the findings to other materials or manufacturing conditions. Future work could explore different additive manufacturing (AM) materials, varying infill densities and alternative forming processes. Practical implications The findings contribute to the advancement of cost-effective and rapid prototyping techniques, reducing reliance on conventional machining. This research holds significant value for manufacturers seeking flexible and sustainable production solutions. Originality/value The study is experimentally performed for sample sizes to identify errors, processes and geometric variation in samples produce by AM tools. The samples are verified for geometry precision.