Determination of k-factor used in sheet metal bending process and simulation of die wear

The aim of the thesis is to determine the k-factor, which is used in sheet metal designs and has an important role in the bending process. In addition, die wear simulation was carried out to determine how many bends the dies used in bending would wear out and at what time intervals they should be checked. The Solidworks program, which is frequently used in the defense industry, has a k-factor in sheet metal bending processes. The k-factor determines the size of the part that will be laser cut before bending. For correct and appropriate bending process closest to tolerance, the k-factor must be determined correctly. It has been revealed which k-factor is more appropriate to use in different thicknesses of AISI 304 stainless steel, st37, AA5754-H111 aluminum sheet materials, which are mostly used in the defense industry. When the literature is scanned, there is very limited information about the k-factor here. The available information is generally valid for material thicknesses from 0.5 mm to 2 mm, for other thicknesses it is only left to guess. After the studies, the k-factors that should be used in bending up to 10 mm in AA5754-H111 and St37 materials and up to 4 mm in AISI 304 stainless steel materials were determined. Verification bending operations regarding the determined k-factor values were carried out and prepared in the form of a comparative table. With this thesis study, it was aimed to create a prediction system for solving the correct k-factor selection and die wear problems that are frequently encountered in sheet metal bending processes.