Experimental Study And Numeric Simulation Of Flanging Process In Sheet Stamping Forming

Flanging is one basic process of stretch stamping forming. In practice, there are so many parts manufactured by flanging process in many fields such as machine, automobile, aerospace, electrical appliance, meter & apparatus and so on. However, compared with other stamping processes such as blanking, drawing and bending, the investigation about flanging process is very limited in existing documents. Therefore, it is necessary to research flanging forming process more comprehensively and further.In the paper, research content and orientation is provided on the basis of developing history and present situation of study on flanging process. There are main research works and some results as follows:1. Experiments of technicsBy a number of experiments of flanging process, some data of process parameters, such as thickness data of sheet metal along workpiece height and pre-manufactured hole size used in practice for a given flanging part, are attained. These data can be used in theoretical investigation of flanging process.2. Theoretical investigationBased on process experiments, using constant volume principle in plastic mechanics and model analysis of Pro/Engineering software, two new and more scientific formulas calculating pre-manufactured hole of flanging are attained; In addition, according to experimental results, slab method in plastic mechanics and material hardening theory, a new formula for hole flanging force is concluded.3. Numerical simulation of hole flangingBased on ABAQUS software, forming process of hole flanging is simulated. By this kind of simulation, the simulating value of pre-manufactured hole can be attained and this can be referred to while designing and testing die. Simultaneously, stress and strain in deformation region can also be analyzed and potential forming defects during the course of deformation can be predicted by it. In addition, using columniform punch and conical punch, different stress-strain distribution and thickness distribution at deformation region of flanging is compared.4. Numerical simulation of opening hole flangingBased on ABAQUS software, forming process of opening hole flanging is simulated. Blank shape and dimension can be optimized by simulation. This can decrease a term of testing die, lower cost of testing die and improve design efficiency.In a word, the content and theory about sheet metal forming process is enriched due to the paper. The data and information in the paper can be consulted and referred to by the technologists participating in sheet metal forming.