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I played around a bit with modeling the bending process and then applying load to the part. There is still a decent margin, but it was not insignificantly reduced due to the residual stresses. So it definitely matters, can't confidently say exactly how much since I just took a quick pass at it...

I found a good study of this topic. See page 10, figure 12 for what I'm worried about. A bit concerning to be loading a part that already has residual stress. Link I've seen statements that the hysteresis loop returns the stress to zero when the sheet is unloaded after being bent, just with...

The Bruhn book has some semi-applicable nuggets (chapts. A13, C3), but I couldn't find anything directly addressing my question. No design charts either, as far as I can tell. My Google efforts have turned up some interesting stuff on FEA modeling of springback after bending, but nothing from a...

rb1957, thanks for weighing in! Option 1 would certainly be the best structural solution. Unfortunately, the specific design I'm working drives us to Option 2 for various reasons (cost, material availability...). The reason I'm a bit concerned is that the bend radius is the tightest within...

First post on Eng-Tips! This is as much a question as it is something I'd like to get a discussion going on. I'll phrase it like a question: When bending sheetmetal, the material at the bend has clearly been stressed past the yield stress but less than the ultimate/failure stress. So there are...