An analysis of forming limit in the elliptic hole-flanging process of sheet metal

Chen, Tsung-Chia

doi:10.1016/j.jmatprotec.2007.04.035

Cited by 26 publications

(8 citation statements)

References 21 publications

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“…In 2004, Chen et al [2] studied the association between punch load and stroke in the direct piercing and repiercing processes for forming a circular flange. Through an analysis and experimental comparison, they discovered that repiercing forming loads were smaller than direct piercing forming loads.…”

Section: Literature Reviewmentioning

confidence: 99%

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Influence of Punch Servo Path on Elliptical Hole Flange Forming

Yu-Teng Zhang, Tsung-Chia Chen

2023

tjjpt

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This study investigated the process of forming an elliptical hole flange by using a SPFC780Y high-strength steel sheet with a material thickness of 1 mm. Three servo motion paths on a servo press were compared with a traditional crank motion path on a conventional press. Four punch motion paths were analyzed, namely a crank motion path on a conventional press (type T), a servo motion path with a 3-mm downward motion followed by a 0.5-mm upward motion (type S3), a servo motion path with a 2-mm downward motion followed by a 0.5-mm upward motion (type S2), and a servo motion path with a 1-mm downward motion followed by a 0.5-mm upward motion (type S1). The finished products of an elliptical hole flanging process were evaluated in terms of thickness, force-displacement, stress, strain, and springback. The results reveal that the products produced using the evaluated servo motion paths were superior to those produced using the evaluated crank motion path.

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Section: Literature Reviewmentioning

confidence: 99%

“…A SPFC780Y high-strength steel sheet with a thickness of 1 mm was used in the present study; its parameters were based on those applied in Huang and Lu [3]. The three angle tensile test specimens used in the present study are depicted in Figure 2 [2], and the parameters of the tensile tests are presented in Figure 3 [2].…”

Section: Sheet Materials Parametersmentioning

confidence: 99%

Influence of Punch Servo Path on Elliptical Hole Flange Forming

Yu-Teng Zhang, Tsung-Chia Chen

2023

tjjpt

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“…Generally, an axisymmetric model is adopted in the finite element (FE) model of the hole flanging process due to the axial symmetry of the round hole. Chen [16] developed a three-dimensional (3D)-FE model to study the formability limitation during the elliptic hole flanging process, where only quarter geometry of the workpiece and the dies was adopted according to the symmetry. The 3D-FE model was developed by Yu et al to study the elliptic hole flanging for advanced high-strength steels [17].…”

Section: Introductionmentioning

confidence: 99%

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

2019

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The large diameter metal shell component (LDMSC) is an important part of gas insulated (metal-enclosed) switchgear (GIS). The LDMSC with multi branches is filled with gas under certain pressure. The plastic forming process is an efficient approach to manufacturing the high reliability LDMSC. The warm flanging process has been widely used to form LDMSC using aluminum alloy. The forming process is characterized by local heating, and the distribution of temperature is strongly inhomogeneous. Although the wall thickness of the shell is 10 mm to 20 mm, the ratio of outer diameter to thickness is more than 40. These present some difficulties in the flanging process and result in some forming defects. Detailed forming characteristics are hard to obtain by analytical and experimental methods. Thus, the through-process finite element (FE) modeling considering heating, forming, unloading, and cooling is one of the key problems to research the manufacturing process of LDMSC. In this study, the through-process FE modeling of the warm flanging process of LDMSC using aluminum alloy was carried out based on the FORGE. The thermo-mechanical coupled finite element method was adopted in the modeling, and the deformation of the workpiece and the die stress were considered together in the modeling. A full three-dimensional (3D) geometry was modeled due to inhomogeneous distribution in all directions for the temperature field. The simulation data of local flame heating could be transferred seamlessly to the simulations of the deforming process, the unloading process, and the cooling process in the through-process FE model. The model was validated by comparison with geometric shapes and forming defects obtained from the experiment. The developed FE model could describe the inhomogeneous temperature field along circumferential, radial, and axial directions for the formed branch as well as the deformation characteristic and the unloading behavior during the warm flanging process. By using the FE model, the forming defects during the flanging process and their controlling characteristics were explored, the evolution of the temperature field through the whole process was studied, and deformation and springback characteristics were analyzed. The results of this study provide a basis for investigating deformation mechanisms, optimizing processes, and determining parameters in the warm flanging process of a large-diameter aluminum alloy shell component.

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“…Previously, several authors [1][2][3][4][5][6][7][8][9][10][11] have studied the hole flanging process and its associated problems. Chen [1] analyzed the forming limit in the elliptical hole flanging process. Hyun et al [2] estimated the hole flangeability for high-strength steel plates.…”

Section: Introductionmentioning

confidence: 99%

Finite element analysis of flange-forming direction in the hole flanging process

Thipprakmas

Phanitwong

2011

Int J Adv Manuf Technol

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The hole flanging process, in which a pre-holed workpiece is expanded by a larger punch, is frequently used in many industries. However, due to the large number of process parameters and their complicated relationships, poor flange edge squareness is commonly generated and results in an increase of secondary operation. In this study, to improve the quality of flange parts, finite element method (FEM) was used to investigate the flange-forming mechanism and effects of upward and downward burr orientation flange-forming directions. Laboratory experiments were performed to validate the accuracy of the FEM simulation results. The FEM simulation results clearly explained the flange-forming mechanism, as well as the effects of flange-forming direction, based on stress distribution analysis. Upward and downward burr orientation flange-forming directions were suitably applied for large and small hole expansion ratios, respectively. In addition, the effects of other process parameters related to the flangeforming direction, including punching clearance, flange thickness, and hole expansion ratios, were also investigated. The FEM simulation results showed good agreement with the laboratory experiments. These results showed that to achieve good squareness at the flange edge, the use of upward and downward burr orientation flange-forming direction and its relation to the other process parameters need to be considered.

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An analysis of forming limit in the elliptic hole-flanging process of sheet metal

Cited by 26 publications

References 21 publications

Influence of Punch Servo Path on Elliptical Hole Flange Forming

Influence of Punch Servo Path on Elliptical Hole Flange Forming

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

Finite element analysis of flange-forming direction in the hole flanging process

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