formulab 0.14.2 → 0.15.0

package/CHANGELOG.md

@@ -5,6 +5,28 @@ All notable changes to this project will be documented in this file.
 The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.0.0/),
 and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
 
+## [0.15.0] - 2026-07-13
+
+### Added
+
+- **`metal/springback()` — sheet-metal springback and overbend compensation.** Computes the
+  springback factor `Ks = R_i/R_f = 4x³ − 3x + 1` (with `x = Y·R_i/(E·T)`), the final radius
+  after unloading, the angle the bend opens up, and the overbend angle needed to land on the
+  target angle (Kalpakjian & Schmid; ASM Metals Handbook Vol. 14B). Material presets mirror
+  `bendAllowance()`'s enum (mildSteel / stainless304 / aluminum5052 / aluminum6061) so a bend
+  workflow keeps one material selection, plus `custom` with explicit yield strength and
+  Young's modulus. Invalid geometry and incomplete `custom` material throw `RangeError`.
+
+  Previously `bendAllowance()` only *warned* that an extreme bend angle "may cause springback
+  issues" without quantifying it; this closes that gap.
+
+- **`MaterialResult.youngsModulus` (GPa).** The material lookup returned yield strength but no
+  elastic modulus, so springback/deflection work could not be driven from a material grade.
+  Reference values (ASM Handbook · MatWeb) added for all 15 grades.
+
+  ⚠️ **Additive to the result object.** Consumers spreading `MaterialResult` into their own
+  types get one extra field; no existing field changed.
+
 ## [0.14.2] - 2026-07-07
 
 ### Documentation

package/README.md

@@ -198,6 +198,7 @@ import { metalWeight, bendAllowance, cutting, bearing } from 'formulab/metal';
 |----------|-------------|
 | `metalWeight()` | Weight calculation for various shapes |
 | `bendAllowance()` | Sheet metal bend allowance |
+| `springback()` | Sheet metal springback / overbend compensation |
 | `flatPattern()` | Flat pattern length calculation |
 | `kFactorReverse()` | K-factor reverse engineering |
 | `pressTonnage()` | Press brake tonnage |

package/dist/metal/index.d.ts

@@ -1,7 +1,8 @@
-export type { MetalShape, MaterialName, MetalWeightInput, MetalWeightResult, BendingMaterial, ShapeType, BendAllowanceInput, BendAllowanceResult, FlatPatternInput, FlatPatternResult, KFactorReverseInput, KFactorReverseResult, PressOperation, BendType, PressTonnageInput, PressTonnageResult, BearingType, BearingInput, BearingResult, BoltCalculationMode, LubricationCondition, BoltInput, BoltResult, CuttingOperation, CuttingInput, CuttingResult, CuttingAlgorithm, CuttingPiece, CuttingStockInput, CuttingPattern, CuttingStockResult, GearCalculationMode, GearInput, GearResult, HardnessScale, HardnessInput, HardnessResult, MaterialCategory, MaterialInput, MaterialResult, MaterialSpec, PressFitInput, PressFitResult, RoughnessScale, RoughnessInput, RoughnessResult, PitchType, ScrewInput, ScrewResult, ScrewSpec, SpringMaterial, SpringInput, SpringResult, ThreadStandard, TapInput, TapResult, ThreadType, ThreadInput, ThreadResult, ThreadSpec, FitType, ToleranceInput, ToleranceResult, VibrationSystem, CrossSection, VibrationMaterial, VibrationInput, FrequencyMode, VibrationResult, WeldProcess, WeldBaseMetal, CrackingRisk, WeldPreheatSourceCode, WeldRecommendationCode, WeldRecommendation, WeldHeatInput, WeldHeatResult, WeldingBaseMetal, JointType, WeldPosition, WeldingInput, WeldingRod, WeldingResult, MaterialStandard, MaterialGradeConverterInput, MaterialGradeConverterResult, PipeStandard, PipeSchedule, PipeSpecInput, PipeSpecResult, FlangeStandard, PressureClass, FlangeSpecInput, FlangeSpecResult, } from './types.js';
+export type { MetalShape, MaterialName, MetalWeightInput, MetalWeightResult, BendingMaterial, ShapeType, BendAllowanceInput, BendAllowanceResult, SpringbackInput, SpringbackResult, FlatPatternInput, FlatPatternResult, KFactorReverseInput, KFactorReverseResult, PressOperation, BendType, PressTonnageInput, PressTonnageResult, BearingType, BearingInput, BearingResult, BoltCalculationMode, LubricationCondition, BoltInput, BoltResult, CuttingOperation, CuttingInput, CuttingResult, CuttingAlgorithm, CuttingPiece, CuttingStockInput, CuttingPattern, CuttingStockResult, GearCalculationMode, GearInput, GearResult, HardnessScale, HardnessInput, HardnessResult, MaterialCategory, MaterialInput, MaterialResult, MaterialSpec, PressFitInput, PressFitResult, RoughnessScale, RoughnessInput, RoughnessResult, PitchType, ScrewInput, ScrewResult, ScrewSpec, SpringMaterial, SpringInput, SpringResult, ThreadStandard, TapInput, TapResult, ThreadType, ThreadInput, ThreadResult, ThreadSpec, FitType, ToleranceInput, ToleranceResult, VibrationSystem, CrossSection, VibrationMaterial, VibrationInput, FrequencyMode, VibrationResult, WeldProcess, WeldBaseMetal, CrackingRisk, WeldPreheatSourceCode, WeldRecommendationCode, WeldRecommendation, WeldHeatInput, WeldHeatResult, WeldingBaseMetal, JointType, WeldPosition, WeldingInput, WeldingRod, WeldingResult, MaterialStandard, MaterialGradeConverterInput, MaterialGradeConverterResult, PipeStandard, PipeSchedule, PipeSpecInput, PipeSpecResult, FlangeStandard, PressureClass, FlangeSpecInput, FlangeSpecResult, } from './types.js';
 export { isMetalWeightInput, isBoltInput } from './guards.js';
 export { metalWeight } from './metalWeight.js';
 export { bendAllowance } from './bendAllowance.js';
+export { springback } from './springback.js';
 export { flatPattern } from './flatPattern.js';
 export { kFactorReverse } from './kFactorReverse.js';
 export { pressTonnage } from './pressTonnage.js';

package/dist/metal/index.d.ts.map

@@ -1 +1 @@
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package/dist/metal/index.js

@@ -3,6 +3,7 @@ export { isMetalWeightInput, isBoltInput } from './guards.js';
 // Functions
 export { metalWeight } from './metalWeight.js';
 export { bendAllowance } from './bendAllowance.js';
+export { springback } from './springback.js';
 export { flatPattern } from './flatPattern.js';
 export { kFactorReverse } from './kFactorReverse.js';
 export { pressTonnage } from './pressTonnage.js';

package/dist/metal/index.js.map

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package/dist/metal/material.d.ts.map

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package/dist/metal/material.js

@@ -1,28 +1,34 @@
+/**
+ * Young's modulus (E, GPa) is the room-temperature reference value for each grade
+ * (ASM Handbook Vol. 1/2 · MatWeb datasheets). It is a material constant, not a
+ * heat-treat-sensitive strength, so one value per grade is the standard treatment.
+ * Required by springback() and any deflection calculation.
+ */
 const MATERIAL_DATA = {
     steel: {
-        'SS400': { density: 7.85, tensileStrength: 400, yieldStrength: 245, elongation: 21, hardness: 'HB 120-160', thermalConductivity: 50, meltingPoint: 1510 },
-        'S45C': { density: 7.85, tensileStrength: 570, yieldStrength: 345, elongation: 17, hardness: 'HB 167-229', thermalConductivity: 49, meltingPoint: 1505 },
-        'SCM440': { density: 7.85, tensileStrength: 980, yieldStrength: 830, elongation: 12, hardness: 'HB 285-352', thermalConductivity: 42, meltingPoint: 1500 },
-        'SK5': { density: 7.85, tensileStrength: 690, yieldStrength: 400, elongation: 20, hardness: 'HRC 58-63', thermalConductivity: 41, meltingPoint: 1495 },
+        'SS400': { density: 7.85, tensileStrength: 400, yieldStrength: 245, youngsModulus: 205, elongation: 21, hardness: 'HB 120-160', thermalConductivity: 50, meltingPoint: 1510 },
+        'S45C': { density: 7.85, tensileStrength: 570, yieldStrength: 345, youngsModulus: 205, elongation: 17, hardness: 'HB 167-229', thermalConductivity: 49, meltingPoint: 1505 },
+        'SCM440': { density: 7.85, tensileStrength: 980, yieldStrength: 830, youngsModulus: 205, elongation: 12, hardness: 'HB 285-352', thermalConductivity: 42, meltingPoint: 1500 },
+        'SK5': { density: 7.85, tensileStrength: 690, yieldStrength: 400, youngsModulus: 205, elongation: 20, hardness: 'HRC 58-63', thermalConductivity: 41, meltingPoint: 1495 },
     },
     stainless: {
-        'SUS304': { density: 7.93, tensileStrength: 520, yieldStrength: 205, elongation: 40, hardness: 'HB 187', thermalConductivity: 16.3, meltingPoint: 1450 },
-        'SUS316': { density: 7.98, tensileStrength: 520, yieldStrength: 205, elongation: 40, hardness: 'HB 187', thermalConductivity: 16.3, meltingPoint: 1400 },
-        'SUS430': { density: 7.70, tensileStrength: 450, yieldStrength: 205, elongation: 22, hardness: 'HB 183', thermalConductivity: 26.1, meltingPoint: 1480 },
+        'SUS304': { density: 7.93, tensileStrength: 520, yieldStrength: 205, youngsModulus: 193, elongation: 40, hardness: 'HB 187', thermalConductivity: 16.3, meltingPoint: 1450 },
+        'SUS316': { density: 7.98, tensileStrength: 520, yieldStrength: 205, youngsModulus: 193, elongation: 40, hardness: 'HB 187', thermalConductivity: 16.3, meltingPoint: 1400 },
+        'SUS430': { density: 7.70, tensileStrength: 450, yieldStrength: 205, youngsModulus: 200, elongation: 22, hardness: 'HB 183', thermalConductivity: 26.1, meltingPoint: 1480 },
     },
     aluminum: {
-        'A6061-T6': { density: 2.70, tensileStrength: 310, yieldStrength: 276, elongation: 12, hardness: 'HB 95', thermalConductivity: 167, meltingPoint: 652 },
-        'A5052-H32': { density: 2.68, tensileStrength: 228, yieldStrength: 193, elongation: 12, hardness: 'HB 60', thermalConductivity: 138, meltingPoint: 649 },
-        'A7075-T6': { density: 2.81, tensileStrength: 572, yieldStrength: 503, elongation: 11, hardness: 'HB 150', thermalConductivity: 130, meltingPoint: 635 },
+        'A6061-T6': { density: 2.70, tensileStrength: 310, yieldStrength: 276, youngsModulus: 68.9, elongation: 12, hardness: 'HB 95', thermalConductivity: 167, meltingPoint: 652 },
+        'A5052-H32': { density: 2.68, tensileStrength: 228, yieldStrength: 193, youngsModulus: 70.3, elongation: 12, hardness: 'HB 60', thermalConductivity: 138, meltingPoint: 649 },
+        'A7075-T6': { density: 2.81, tensileStrength: 572, yieldStrength: 503, youngsModulus: 71.7, elongation: 11, hardness: 'HB 150', thermalConductivity: 130, meltingPoint: 635 },
     },
     copper: {
-        'C1100': { density: 8.94, tensileStrength: 220, yieldStrength: 70, elongation: 45, hardness: 'HB 45', thermalConductivity: 391, meltingPoint: 1083 },
-        'C2600': { density: 8.53, tensileStrength: 325, yieldStrength: 95, elongation: 65, hardness: 'HB 55-80', thermalConductivity: 120, meltingPoint: 940 },
-        'C5191': { density: 8.80, tensileStrength: 520, yieldStrength: 195, elongation: 45, hardness: 'HB 160', thermalConductivity: 67, meltingPoint: 1025 },
+        'C1100': { density: 8.94, tensileStrength: 220, yieldStrength: 70, youngsModulus: 115, elongation: 45, hardness: 'HB 45', thermalConductivity: 391, meltingPoint: 1083 },
+        'C2600': { density: 8.53, tensileStrength: 325, yieldStrength: 95, youngsModulus: 110, elongation: 65, hardness: 'HB 55-80', thermalConductivity: 120, meltingPoint: 940 },
+        'C5191': { density: 8.80, tensileStrength: 520, yieldStrength: 195, youngsModulus: 110, elongation: 45, hardness: 'HB 160', thermalConductivity: 67, meltingPoint: 1025 },
     },
     titanium: {
-        'Ti-6Al-4V': { density: 4.43, tensileStrength: 950, yieldStrength: 880, elongation: 14, hardness: 'HRC 36', thermalConductivity: 6.7, meltingPoint: 1660 },
-        'CP-Ti Grade2': { density: 4.51, tensileStrength: 345, yieldStrength: 275, elongation: 20, hardness: 'HB 200', thermalConductivity: 16.4, meltingPoint: 1668 },
+        'Ti-6Al-4V': { density: 4.43, tensileStrength: 950, yieldStrength: 880, youngsModulus: 113.8, elongation: 14, hardness: 'HRC 36', thermalConductivity: 6.7, meltingPoint: 1660 },
+        'CP-Ti Grade2': { density: 4.51, tensileStrength: 345, yieldStrength: 275, youngsModulus: 105, elongation: 20, hardness: 'HB 200', thermalConductivity: 16.4, meltingPoint: 1668 },
     },
 };
 export function getCategories() {
@@ -54,6 +60,7 @@ export function material(input) {
         density: spec.density,
         tensileStrength: spec.tensileStrength,
         yieldStrength: spec.yieldStrength,
+        youngsModulus: spec.youngsModulus,
         elongation: spec.elongation,
         hardness: spec.hardness,
         thermalConductivity: spec.thermalConductivity,

package/dist/metal/material.js.map

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package/dist/metal/springback.d.ts

@@ -0,0 +1,28 @@
+import type { SpringbackInput, SpringbackResult } from './types.js';
+/**
+ * Sheet-metal springback: how much a bend elastically opens up after the tool is
+ * released, and how far to overbend so the part lands on the target angle.
+ *
+ * The elastic core of a bent sheet recovers on unloading, so the final radius is
+ * always larger (and the final angle shallower) than the tool's. The recovery
+ * grows with the R/t ratio and with the yield-strength-to-stiffness ratio Y/E —
+ * which is why aluminium springs back far more than steel at the same geometry.
+ *
+ * @formula x  = Y · R_i / (E · T)                (dimensionless)
+ * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, ≤ 1)
+ * @formula R_f = R_i / Ks · θ_final = θ_tool · Ks ⇒ θ_overbend = θ_target / Ks
+ * @reference Kalpakjian & Schmid, "Manufacturing Engineering and Technology",
+ *            springback equation for pure bending (also in ASM Metals Handbook
+ *            Vol. 14B, Sheet Forming). Valid for R_i > 2T, where the neutral axis
+ *            sits at mid-thickness; θ scales with Ks because the neutral-axis arc
+ *            length is conserved through unloading.
+ * @units thickness/bendRadius mm · bendAngle degrees · yieldStrength MPa · elasticModulus GPa
+ * @validation thickness > 0, bendRadius > 0, 0 < bendAngle < 180; for material
+ *             'custom', yieldStrength > 0 and elasticModulus > 0 are required.
+ * @param input - Geometry plus material (preset or custom Y/E)
+ * @returns Springback factor, final radius, springback angle, and overbend angle
+ * @throws {RangeError} thickness, bendRadius or bendAngle out of range
+ * @throws {RangeError} material is 'custom' but yieldStrength/elasticModulus missing or non-positive
+ */
+export declare function springback(input: SpringbackInput): SpringbackResult;
+//# sourceMappingURL=springback.d.ts.map

package/dist/metal/springback.d.ts.map

@@ -0,0 +1 @@
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package/dist/metal/springback.js

@@ -0,0 +1,80 @@
+import { roundTo } from '../utils.js';
+/**
+ * Yield strength (MPa) and Young's modulus (GPa) presets, matched to the material
+ * enum used by bendAllowance() so a bend workflow keeps one material selection.
+ * Room-temperature reference values (ASM Handbook · MatWeb datasheets).
+ */
+const MATERIAL_PROPS = {
+    mildSteel: { yieldStrength: 250, elasticModulus: 200 }, // A36 / 1018
+    stainless304: { yieldStrength: 215, elasticModulus: 193 }, // 304 annealed
+    aluminum5052: { yieldStrength: 193, elasticModulus: 70 }, // 5052-H32
+    aluminum6061: { yieldStrength: 276, elasticModulus: 69 }, // 6061-T6
+};
+/**
+ * Sheet-metal springback: how much a bend elastically opens up after the tool is
+ * released, and how far to overbend so the part lands on the target angle.
+ *
+ * The elastic core of a bent sheet recovers on unloading, so the final radius is
+ * always larger (and the final angle shallower) than the tool's. The recovery
+ * grows with the R/t ratio and with the yield-strength-to-stiffness ratio Y/E —
+ * which is why aluminium springs back far more than steel at the same geometry.
+ *
+ * @formula x  = Y · R_i / (E · T)                (dimensionless)
+ * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, ≤ 1)
+ * @formula R_f = R_i / Ks · θ_final = θ_tool · Ks ⇒ θ_overbend = θ_target / Ks
+ * @reference Kalpakjian & Schmid, "Manufacturing Engineering and Technology",
+ *            springback equation for pure bending (also in ASM Metals Handbook
+ *            Vol. 14B, Sheet Forming). Valid for R_i > 2T, where the neutral axis
+ *            sits at mid-thickness; θ scales with Ks because the neutral-axis arc
+ *            length is conserved through unloading.
+ * @units thickness/bendRadius mm · bendAngle degrees · yieldStrength MPa · elasticModulus GPa
+ * @validation thickness > 0, bendRadius > 0, 0 < bendAngle < 180; for material
+ *             'custom', yieldStrength > 0 and elasticModulus > 0 are required.
+ * @param input - Geometry plus material (preset or custom Y/E)
+ * @returns Springback factor, final radius, springback angle, and overbend angle
+ * @throws {RangeError} thickness, bendRadius or bendAngle out of range
+ * @throws {RangeError} material is 'custom' but yieldStrength/elasticModulus missing or non-positive
+ */
+export function springback(input) {
+    const { thickness, bendRadius, bendAngle, material = 'mildSteel' } = input;
+    if (!(thickness > 0)) {
+        throw new RangeError('thickness must be greater than 0');
+    }
+    if (!(bendRadius > 0)) {
+        throw new RangeError('bendRadius must be greater than 0');
+    }
+    if (!(bendAngle > 0) || bendAngle >= 180) {
+        throw new RangeError('bendAngle must be between 0 and 180 degrees');
+    }
+    let yieldStrength;
+    let elasticModulus;
+    if (material === 'custom') {
+        yieldStrength = input.yieldStrength ?? NaN;
+        elasticModulus = input.elasticModulus ?? NaN;
+        if (!(yieldStrength > 0)) {
+            throw new RangeError('yieldStrength must be greater than 0 for custom material');
+        }
+        if (!(elasticModulus > 0)) {
+            throw new RangeError('elasticModulus must be greater than 0 for custom material');
+        }
+    }
+    else {
+        ({ yieldStrength, elasticModulus } = MATERIAL_PROPS[material]);
+    }
+    // Y is MPa and E is GPa — convert E so x stays dimensionless.
+    const eMPa = elasticModulus * 1000;
+    const x = (yieldStrength * bendRadius) / (eMPa * thickness);
+    const springbackFactor = 4 * x ** 3 - 3 * x + 1;
+    const finalRadius = bendRadius / springbackFactor;
+    const overbendAngle = bendAngle / springbackFactor;
+    const springbackAngle = overbendAngle - bendAngle;
+    return {
+        springbackFactor: roundTo(springbackFactor, 4),
+        finalRadius: roundTo(finalRadius, 2),
+        springbackAngle: roundTo(springbackAngle, 2),
+        overbendAngle: roundTo(overbendAngle, 2),
+        yieldStrength,
+        elasticModulus,
+    };
+}
+//# sourceMappingURL=springback.js.map

package/dist/metal/springback.js.map

@@ -0,0 +1 @@
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package/dist/metal/types.d.ts

@@ -50,6 +50,22 @@ export interface BendAllowanceResult {
     minBendRadius: number;
     warnings: string[];
 }
+export interface SpringbackInput {
+    thickness: number;
+    bendRadius: number;
+    bendAngle: number;
+    material?: BendingMaterial;
+    yieldStrength?: number;
+    elasticModulus?: number;
+}
+export interface SpringbackResult {
+    springbackFactor: number;
+    finalRadius: number;
+    springbackAngle: number;
+    overbendAngle: number;
+    yieldStrength: number;
+    elasticModulus: number;
+}
 export interface FlatPatternInput {
     shapeType: ShapeType;
     thickness: number;
@@ -261,6 +277,7 @@ export interface MaterialResult {
     density: number;
     tensileStrength: number;
     yieldStrength: number;
+    youngsModulus: number;
     elongation: number;
     hardness: string;
     thermalConductivity: number;
@@ -270,6 +287,7 @@ export interface MaterialSpec {
     density: number;
     tensileStrength: number;
     yieldStrength: number;
+    youngsModulus: number;
     elongation: number;
     hardness: string;
     thermalConductivity: number;

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package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "formulab",
-  "version": "0.14.2",
+  "version": "0.15.0",
   "description": "Manufacturing & Engineering calculation formulas library - 182 industrial calculations across 15 domains for OEE, Cpk, SPC, FMEA, Nelson Rules, metal weight, CNC machining, GD&T, battery, environmental, pipe flow, logistics, IE time study, and more",
   "type": "module",
   "main": "./dist/index.js",