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Materials Today: Proceedings 2 (2015) 1934 1941
Research Scholar, Department of Mechanical Engineering,Maulana Azad National Institute of Technology, Bhopal,462051, India
b
Professor, Department of Civil Engineering,Maulana Azad National Institute of Technology, Bhopal, 462051, India
c
Scientist,Computer Simulation & Design Centre,Advanced Materials Processes and Research Institute,Bhopal,462064, India
Abstract
The effect of blank holding force on the stretch flanging process was investigated using finite element simulation and
experimental analysis. Finite element model was used to study the effect of blank holding forces on punch load and forming
kinematics. An aluminum alloy 5052 sheet of 0.5 mm thickness was employed for this work. Blank holding force has a great
effect on punch load and significant influence on forming kinematics. Validation of FEM results were obtained by conducting
experiments. A very good agreement was obtained between FEM simulation results in terms of punch load and final shape which
shows the accuracy of present finite element model.
2014Elsevier
The Authors.
Ltd. All rights reserved.
2015
Ltd. AllElsevier
rights reserved.
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Keywords: Stretch flanging; blank holding force; finite element simulation; punch load; aluminum alloy.
1. Introduction
Aluminum alloys find automotive and air craft applications due to their high specific strength, high fatigue
strength and excessive corrosion resistance. Automotive components are usually manufactured of aluminum alloys
by using sheet metal forming processes. Flanging is one of the important sheet metal forming processes which is
* Corresponding author. Tel.:+91-0755-2457105; fax: +91-0755-2457042.
E-mail address:yogesh_dewang@yahoo.co.in
1935
widely applied in automobile industry. Many researchers in past have utilized the aluminum alloys in stretch
flanging process and studied different aspects of the process. Asnafi [1] studied vertical stretch flanging process
and found that fracture limit has increased with increase in parameters such as plastic strain ratio, strain hardening
exponent, uniform strain.Worswick and Finn [2] have carried out finite element simulation of stretch flanging
process using AA 5182O sheet of 1.2 mm in order to examine the effect of different yield criterion on the
predicted strains within stretch flange and determined the appropriate formability criteria for use in modelling
stretch flanges. Chen et al. [3] have employed a multiscale finite element (FE) damage percolation model (GTN
model) in order to simulate stretch flange forming of aluminum alloys AA 5182 and AA 5754 and studied the
effect of void nucleation strain on formability prediction through parametric study. Butcher et al.[4] carried out
finite element simulation of stretch flange forming of AA5182 of 1.6 mm using upper and lower bound damage
based material models for prediction of formability and effect of void damage during forming operations. Simha et
al.[5] have utilized an extended stress based forming limit curve in order to predict necking in stretch flange
forming of 1.6 mm thick AA 5754 and 1 mm thick AA 5182 aluminum alloy.Bhoyar et al. [6] carried finite
element analysis of superplastic forming process for front fender car panel ,which also an application of stretch
flanging process, for prediction of formability of commercial AA 5182 sheets .Dewang et al.[7] have predicted the
location of edge crack occurred in stretch flange of AA 5052 in the stretch flange using finite element simulation.
The objective of the present study is to investigate the influence of blank holding force on punch load variation
and maximum load during stretch flange forming of 0.5 mm thick AA 5052 using finite element simulation.
Nomenclature
c
D
E
F
R
Rd
L
l
t
U
w
punch-die clearance
ductile damage parameter
youngs modulus
blank holding force
flange radius
die profile radius
initial flange length
length of straight portion
flange thickness/ sheet thickness
punch displacement
flange width
mass density
poissons ratio
2. Materials behavior
In order to determine the mechanical properties of the workpiece material AA 5052, the tensile samples
were prepared as per standard methods of tensile testing method E8/E8M-11 ASTM.Fig. 1 shows the tensile
samples (along rolling direction) for uniaxial tensile testing, which are prepared by CNC wire cutting machine. The
tests were carried out under a displacement control at a constant rate of 0.16667 per second. The chemical
composition of aluminum alloy 5052 sheet of 0.5 mm thickness is given in Table 1. For FE analysis a non-linear
stress strain curve was considered as shown in fig.2[7] .It was assumed that aluminum alloy sheet follows elastoplastic behavior with isotropic hardening rule.
Table 1 Chemical composition of AA 5052[7]
Element
Wt.%
Si
0.1224
Fe
0.1964
Mg
2.418
Mn
0.07688
Cu
0.03618
Cr
0.1688
Ni
0.00398
Zn
0.04454
Al
95.70
1936
300
-0.05
250
200
150
100
50
0
-50
-100
Fig. 1 AA 5052 H-32 0 degree tensile samples
0.05
0.1
0.15
0.2
True Strain
Punch
Blank-holder
1937
Die
The blank material is assumed to be an elastoplastic material with isotropic hardening. The material
properties of the blank used in the simulation are as follows: = 2680 kg/m3, E = 70.3 GPa, = 0.33. [7].Friction is
modelled between the blank and the tool interfaces by using the Coulomb assumption in all cases as = 0.1[7]. The
damage initiation criteria (D) are defined as function of equivalent plastic strain for prediction of failure in flange.
The geometrical dimensions of punch, die, holder and sheet metal blanks are taken similar as that of experiments.
In the present study there are three different cases of blank holding conditions which are considered. In all
three cases die remains fixed and punch travels along vertical downward direction for formation of stretch flange.
First of all the case (C1) is considered which consists of rigidly clamping the workpiece between die and blank
holder .The model of case (C1) was obtained by restricting the upward motion of the blank holder along punch
travel direction which in turn also restricts the motion of workpiece. The model of case (C2) was made by applying
a blank holding force of zero intensity on the blank holder and now by allowing the displacement of blank holder
along punch travel direction. Finally, the model of case (C3) was obtained by applying various constant blank
holding forces on blank holder in order to obtained change in thickness without restriction of displacement of blankholder along punch travel direction.
5. Results & discussion
5.1 Load and forming kinematics
5.1.1 stretch-flanging with rigid blank holder
Case (C1) is considered to analyze the forming kinematics during stretch flanging process in the first
condition. The evolution of the punch loadpunch travel relationship consists of three different stages. The whole
punch loadpunch displacement relationship is shown in fig.5. In the first stage (1) the punch load starts to increase
more or less in linear manner which shows that for bending of sheet requires higher load from unbent position with
increase in punch displacement. It can be seen through figure that punch load arrives at maximum value at a punch
displacement between 2 to 3 mm. The occurrence of the maximum load signifies that crack has initiated in the
workpiece .The second stage (II) involves the further displacement of punch with fall in punch load gradually and
1938
500
II
III
450
PUNCH LOAD (N)
400
C1
350
300
250
200
C2
150
100
50
0
10
15
20
25
Fig.5. Punch load versus punch displacement for cases (C1) and (C2)
non-linearly which may be due to crack initiation or slipping of punch over the sheet. It is observed that punch load
decreases up to 5-6 mm of punch displacement. After stage (II), the punch load further decreases may due to
complete crack propagation of crack or sliding of punch over the flange in stage (III).
5.1.2 Stretch-flanging without blank holding force
One of the other cases which are extreme case of the blank holding condition was also analyzed. The
relationship between punch load and punch travel for this case is shown in fig.5.It is observed from the
superimposition of the case (C1) and case (C2) shows the reduction of the first stage of case (C1) by approximately
53 % in terms of punch travel. The peak load in case (C1) arrives at 53 % before case (C2) in terms of punch
displacement and peak load decreases by 71 %.In the stage 2 of case (C2) the load decreases gradually and
diminishes to nearly zero values and in the third stage punch load continues to remain constant at lowest values.
This shows a significant effect of the blank holding force upon punch load as well as on forming kinematics.
450
80 N (FEM)
100 N (FEM)
120 N (FEM)
140 N (FEM)
160 N (FEM)
400
350
300
250
200
150
100
50
0
0
10
15
20
25
1939
6.000E+02
5.000E+02
4.000E+02
3.000E+02
L= 20 mm
L= 30 mm
L = 40 mm
2.000E+02
1.000E+02
0.000E+00
60
80
100
120
140
160
PUNCH LOAD
4.500E+02
4.000E+02
C= 1 mm
3.500E+02
C= 1.5 mm
3.000E+02
C = 2 mm
2.500E+02
C= 2.5 mm
C= 3 mm
2.000E+02
1.500E+02
1.000E+02
5.000E+01
0.000E+00
0
50
100
150
200
1940
500
450
400
350
300
250
200
150
100
50
0
0
10
15
20
25
1941
6. Conclusions
Finite element simulations had been carried to investigate the effect of blank holding force in the stretch
flanging process. The following are the conclusions drawn from the study.
i.
ii.
Blank holding force has a significant effect upon maximum load as well as on forming kinematics. The
punch load increases with increase in blank holding force for each blank holding condition.
Validation of simulation results with experimental one are done for the rigid blank holder condition. A very
good agreement is obtained between results of FEM simulation and experiments in terms of maximum
punch load and final deformed shape.
References
[1] Asnafi N.On stretch and shrink flanging of sheet aluminium by fluid forming.J. of Mater ProcTechnol 1999;96:198- 214.
[2] Worswick M J,Finn M J.The numerical simulation of stretch flange forming. Int J Plast 2000; 16:701-720.
[3] Chen Z, Worswick M J, Pilkey A K, Lloyd D J. Damage percolation during stretch flange forming of aluminum alloy sheet. J Mech Phy
Solids 2005; 53:2692-2717.
[4] Butcher C, Chen Z, Worswick W.A lower bound damage-based finite element simulation of stretch flange forming of Al-Mg alloys. Int J
Frac 2006; 142:289-298.
[5] Simha CHM,Grantab R ,Worswick M J .Application of an extended stress-based forming limit curve to predict necking in stretch flange
forming. J Manuf Sci Eng 2008;130: 1-11.
[6] Bhoyar PK, Sedani CM, Agrawal MK.FEA of superplastically formed front fender car panel.Adv Matr Manuf Charac 2013;3:237-242.
[7] Dewang Y, Hora M S, Panthi SK .Finite element analysis of non-axisymmetric stretch flanging process for prediction of location of failure.
Proc Matr Sci 2014;5:2054-2062.