Development of an inverse routine to predict residual stresses in the material based on a bending test

Bending and reverse bending are the dominant material deformations in roll forming, and hence property data derived from bend tests could be more relevant than tensile test data for numerical simulation of a roll forming process. Recent investigations have shown that residual stresses change the material behavior close to the yield in a bending test. So, residual stresses introduced during prior steel processing operations may affect the roll forming process, and therefore they need to be included in roll forming simulations to achieve improved model accuracy. Measuring the residual stress profile experimentally is time consuming and has limited accuracy while analytical models that are available require detailed information about the pre-processing conditions that is generally not available for roll forming materials. The main goal of this study is to develop an inverse routine that determines a residual stress profile through the material thickness based on experimental pure bend test data. A numerical model of the skin passing (temper rolling) process is performed to introduce a residual stress profile in DP780 steel sheet. The skin passed strips are used in a pure bending simulation to record moment-curvature data and this data is then applied in an inverse analysis to predict the residual stress profile in the material. Comparison of the residual stress profile predicted by the inverse routine with that calculated by finite element analysis (FEA) indicates an inverse approach combined with pure bend test may present an alternative to predict residual stresses in sheet metals.