U-bending tests are the most common method to predict springback and are influenced by the process and geometrical variables in addition to material behaviour. It needs a numerical study at a high level with many variables to reduce try-out time and loop. In this study, the U-bending test of DC01 steel has been researched numerically and experimentally to govern the influential parameters. The numerical analysis was conducted using AutoForm-Sigma code. The die radius has an excessive influence on the change of flange angle than the punch radius, but the punch radius has the greatest influence on the variation of the sidewall angle. The coefficient of friction played a great impact on both flange and sidewall angle deviation and its influence grows stronger as the blank holding force increases.

The currently available anti-buckling fixtures for uniaxial tension-compression testing of sheet metal could not fulfill the requirements and standards. In this study, a unique system of the anti-buckling fixtures to enable getting accurate and repeatable isotropic and kinematic behavior of sheet metal was designed. The front surface of the specimen was fully supported during the initial position, tension, and compression and free from any buckling. Because using acrylic blocks, has a greater level of optical clarity, there was the possibility to measure the deformation on the front surface of the specimen using a digital image correlation system. The special pusher vice with compressed spring was attached to the fixture to avoid misalignment and calculating supplementary forces related to uniaxial direction. Furthermore, the new fixture was simple, flexible, and suitable for any universal testing machine.

Because of thin wall thicknesses and closed bottom ends of the extruded aerosol can, the necking limit analysis needs intensive investigation. The numerical analysis of the necking process of 0.45 mm thickness pure aluminum aerosol can was carried out. The result indicated that the length of the aerosol can wall, which is not fixed by the bottom die and the angle of inclination of necking tools are important factors that affect the development of deformation boundary limits due to plastic instability of local buckling. The fraction of taper angle of tool becomes more series parameter while necking at larger free length and it needs more concentration. Instead, the ratio of necking tool displacement to the total free length to initiate buckling was increased while increasing free length.