Experimental studies on incremental hole flanging of steel sheets

ABSTRACT Incremental Hole-Flanging (IHF) process has various applications in rapid prototyping and low volume production of conical and vertical flanges in sheet metal parts. Therefore, understanding mechanics and failure strategies in IHF is very important for successful forming without cracks. In this paper, Deep Drawing (DD) steel blanks with pre-cut hole of 40 and 70 mm diameter are used for multistage conical hole flanging. Conical hole flanges are formed on CNC milling machine with starting angle 60° to final angle 90° with an increment of 10°. The experimental results showed a crack at 80° flange angle with the blank of 40 mm pre-cut hole. The blank with 70 mm-pre-cut hole has no such crack behaviour even at 90° flange angle. The paper also discusses the variation of flange height, surface roughness and forming forces in IHF of DD steel sheets.

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