Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Kumar, Surendra; Ahmed, Meraj; Panthi, S.K.

doi:10.1007/s43452-020-00016-2

Cited by 10 publications

(5 citation statements)

References 43 publications

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“…Punching and hole-expansion experiments using Dual Phase steel were conducted to validate the conclusions. Kumar et al [15] used finite element simulations and experiments to investigate the effect of punch head profiles on deformation behavior of AA5052 alloy sheet in stretch-flanging processes. Six different punch geometries were used.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes

Hwang

Pham

Tsui

2021

Metals

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Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing and hydro-flanging is proposed. An internal pressured fluid is used as the supporting medium instead of a rigid die. Three kinds of punch head shapes are designed to explore the thickness distribution of the flanged tube and the fluid leakage effects between the punch head and the flanged tube in the hydro-flanging process. A finite element code DEFORM 3D is used to simulate the tube material deformation behavior and to investigate the formability of the hydro-flanging processes of aluminum alloy tubes. The effects of various forming parameters, such as punch shapes, internal pressure, die hole diameter, etc., on the hydro-flanged tube thickness distributions are discussed. Hydro-flanging experiments are also carried out. The die hole radius is designed to make the maximum internal forming pressure needed smaller than 70 MPa, so that a general hydraulic power unit can be used to implement the proposed hole flanging experiments. The flanged thickness distributions are compared with simulation results to verify the validity of the proposed models and the designed punch head shapes.

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Section: Introductionmentioning

confidence: 99%

Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes

Hwang

Pham

Tsui

2021

Metals

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“…Kumar et al investigated the influence of different punch profiles (i.e. cylindrical, conical, hemispherical, two step, three step and six step punch) on deformation behaviour of AA5052 sheet in concave flanging [25]. It was found that the hemispherical punch profile gives better results as compared to other profile in terms of edge crack length and strain distribution.…”

Section: Effect Of Geometrical and Process Parameters On Stretch Flan...mentioning

confidence: 99%

Effects of processes parameters on spring back, wrinkles and cracks in different flanging processes: A Review

Kumar

Singh²,

Soni

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Flanging is an important type of sheet metal bending process. In present review, an effort was made to explore the contributions of various researchers to drawn out the cause of defects in the flanging process. Several parameters such as geometrical, material and process parameters affect the formability of the flanging process. In straight flanging process, spring back (due to elastic recovery) is a major problem that affects dimensional and geometrical accuracy of a bent component. Several factors are responsible for springback such as – profile radius of punch and die, bend angle, thickness of sheet, clearance between punch and die, blank-holder force, Young’s modulus, n-value, yield stress, plastic anisotropy of materials, velocity of punch etc. In shrink flanging process, wrinkling is the prime concern that occurs due to the excessive compressive stress in the flange portion. It is mostly affected by mechanical properties of material (R-value, n–value etc.), geometry of the tools and blank, process parameters. In stretch flanging process, the effect of material parameters is found to be less as compared to geometrical parameters for crack initiation and thinning.

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“…In Fig. 1 True stress-true strain curve of AA 5052 [34] the simulation, die, blank-holder and punch were considered as rigid bodies and modeled with R3D4 element. R3D4 are rigid 3D four-nodded elements and formed the master surfaces during the contact definition conditions.…”

Section: Finite Element Modeling and Simulationmentioning

confidence: 99%

“…In this study, effect of the sheet width and the die radius are investigated on the aluminum alloy AA-5052 sheet metal blank. Effect of others parameters are also studied and has been published in the other manuscript [34]. The work was carried out by ABAQUS/Explicit software to predict the edge crack location and propagation, thickness distribution in the flange, forming load and strain distribution.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Crack and Thinning Behavior of Aluminum Alloy 5052 Sheet in Stretch Flanging Process

Kumar

Ahmed

Panthi

2020

J Fail. Anal. and Preven.

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Stretch flanging is the important sheet metalforming process which is widely used in automobile and aerospace sectors. The formability of sheet metal depends on various parameters such as material properties, geometry of the tool setup and process parameters. In the present work, effects of different die radius and sheet width on deformation behavior of sheet are studied by FEM simulation and experiments. The predicted FEM results are presented in the form of edge crack location and its propagation, crack length, forming load and strain distribution in sheet along the die profile radius. This study indicates that crack length increases with increase in the sheet width, while the crack length decreases with increase in the die radius. It is found that the crack propagation in stretch flanging process is affected by the strain distribution in sheet and this distribution of strain depends on many parameters. The crack initiates during deformation of the sheet at the die corner edge and propagates toward the center of the sheet along the die profile radius. Simulation results are compared with the experimental one in terms of crack length and variation in sheet thickness. FE simulation results are found in very good agreement with experimental results. Fractography study is also presented in terms of size, shape of the dimples along with their distribution on the fractured surface. Keywords Stretch flanging process Á Finite element simulation Á Edge crack Á Crack length Á Forming load Á Strain and thickness distribution Á Fractography

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Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Cited by 10 publications

References 43 publications

Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes

Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes

Effects of processes parameters on spring back, wrinkles and cracks in different flanging processes: A Review

Investigation on the Crack and Thinning Behavior of Aluminum Alloy 5052 Sheet in Stretch Flanging Process

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