Finite Element Analysis of Thin Sheet Metal Bending Process

Abstract The paper presents the numerical analysis of the bending process of thin DC01 steel sheets using the finite element method implemented in the ABAQUS/CAE software. The developed three-dimensional model included the definition of the material’s elastic and plastic properties, frictional contact conditions, and geometric nonlinearity effects. The distributions of principal, secondary, and directional strains (εₓ, εᵧ) were analyzed, highlighting the critical regions in the contact area with the punch. The maximum strain values, in the range of 1.3–1.6 mm/mm, indicate severe plastic deformation regimes typical of intensive bending processes. The results confirm the ability of the finite element method to reproduce the real material behavior and provide a solid basis for optimizing technological parameters. The study demonstrates the usefulness of numerical simulation as an essential stage in computer-aided design of sheet metal forming processes.