Binder force effect on stretch flange forming of aluminum alloy

Dewang, Yogesh; Panthi, S.K.; Hora, M. S.

doi:10.1080/10426914.2019.1655154

Cited by 10 publications

(7 citation statements)

References 13 publications

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“…It was noted that the major strain increases with increase in flange length (L) and decrease with clearance (C). Effect of binder force and thickness distribution in stretch flange process using FEM simulation was also investigated and validated with experimental one [38]. Circumferential strain, crack extension and thinning increasing with increasing the binder force for same process.…”

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

confidence: 98%

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

confidence: 98%

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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“…Die was constrained in all directions to represent it as a stationary body whereas the punch moves only in downward z-direction to deform the sheet and form the flange in all cases of simulation. The constant force of 20 kN was applied at the blank-holder [7,31]. The clearance between the punch and die was considered as 1 mm [5,6] and coefficient of friction was assumed to be 0.1 in all the cases [7,23,26,31,42].…”

Section: Fem Modelling and Simulationmentioning

confidence: 99%

“…The flange curvature of the sheet is like a concave bend line and it stretches the sheet metal circumferentially along the bending line. Hoop strain is the main parameter that is responsible for failure of flange [4,6,7]. If this strain reaches a certain limit, it leads to a crack in sheet.…”

Section: Introductionmentioning

confidence: 99%

“…Steel, copper and aluminium specimen were used to perform the tensile test experiments and to compare the FEM results in terms ductile fracture strain at various fracture location. It can be summarise from the literature review that in stretch flanging process [14,[37][38][39] deformation behaviour of sheet and fracture in sheet have been widely investigated considering various parameters such as material parameters [1,17,23], geometrical parameters [1,4,11,13,16,23,26,31,37,40,41], blank holding force [7,31], friction coefficient [7,23,26,31,42]. Different punch shape has also been used in other sheet metal forming processes such as stretch, shrink, hole flanging and deep drawing process [2, 27-29, 33, 35, 36, 41].…”

Section: Introductionmentioning

confidence: 99%

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

Kumar

Ahmed

Panthi

2020

Archiv.Civ.Mech.Eng

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Stretch flanging is a type of bending process widely used in automobile and aerospace industries. Forming of the stretch flange is mainly affected by three important parameters: materials of the sheet, the geometry of tools and different process parameters. This work focuses on the effect of punch profile on deformation behavior of AA5052 alloy sheet to form the stretch flange. Six punches of different geometry i.e. cylindrical, two stepped, three stepped, six stepped, conical and hemispherical are used. Results are presented in the form of edge crack in the sheet at edge corner and its propagation towards center, forming load comparison for different punch profile and distribution of radial and circumferential strain in the sheet. It is observed that the punch profile has a considerable effect on the deformation behavior of the sheet. Circumferential strain, radial strain and load requirement to form the flange are found to be minimum in hemispherical punch profile as compared to other punch profiles. Experiments are performed to validate the FE simulation results and results are found in very good agreement in terms of edge crack length. Fractography study shows uniform and large number of small size dimples at the fractured surface for hemispherical and conical punch profile.

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“…P. Hu et al generated couple of analytical models for shrink and stretch anging processes for calculation of blank size [6]. Yogesh Dewang et al carried out the experimental and numerical simulation work for the analysis of binder force effect in stretch anging of AA5052 sheet [10]. G. Ellen et al created the analytical model for the evaluation of circumferential strain and proposed a semi-empirical failure criteria for analysis of wrinkling in shrink anging process [11].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the effect of different punch shapes on thickness distribution of AA5052 sheet in stretch flanging process

Kumar¹,

Panthi

Ahmed³

et al. 2022

Preprint

Self Cite

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Flanging is a well-known process in sheet metal forming (SMF) process, which is highly used in automobile industry and in manufacturing of home appliances. The effectiveness of the flanging process depends on the geometry of tools, material properties etc. In the present research assessment, influence of punch shape on thickness variation in aluminium alloy sheet in stretch flanging (SF) process is presented, which is major challenge of this process. Six types of punches are used in the present work i.e. spherical, conical, cylindrical, 2 step, 3 step and 6 step. Punch of shape is an important part of tooling that affects the deformation behaviour of blank. FEM simulation work is carried out for the assessment of thickness and strain distribution in the flange portion (along the die profile radius and midsection (centre) of blank) in stretch flanging process. The results are validated with experiments that observed in a very good agreement. The reduction in thickness of blank is found minimum in hemispherical punch along the die profile radius and in the midsection of blank as compared to other punch geometry. Thus, it is concluded from this work, based on the reduction of thickness of blank, that the hemispherical punch profile is more suitable in the product design by stretch flanging process.

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Binder force effect on stretch flange forming of aluminum alloy

Cited by 10 publications

References 13 publications

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

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

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

Analysis of the effect of different punch shapes on thickness distribution of AA5052 sheet in stretch flanging process

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