Prediction of Optimal Punch Displacement in Cam-Forming of Side-Bead Considering Material Properties and Sheet Thickness

In this study, an optimal punch displacement model was developed for side-bead forming using the cam-forming process. Finite element simulations were conducted under various sheet thicknesses and material properties to evaluate forming error based on bead radius and sheet height. To derive the optimal cam displacements, a normalized scoring method was applied, and the most accurate cam displacements were identified. The resulting displacements were modeled using multivariable regression analysis by considering four independent variables: yield strength, ultimate tensile strength, hardening exponent, and sheet thickness. The model was simplified without interaction terms to enhance applicability. The results showed that sheet thickness had a dominant effect on punch displacement when compared with material properties. The proposed model effectively predicts the punch displacement required to achieve optimal forming outcomes. This approach provides insights for optimization in side-bead forming applications involving various materials and thicknesses.