A Study of Hole Flanging-Upsetting Process

Abstract

A combined process of hole flanging and flange upsetting was proposed. Both elastic-plastic FEM and experiments were employed to analyze the process. A 2mm thick 08AL sheet with 120mm outer diameter and 24.6mm center hole diameter was used as the blank. The effect of the Rf and the Rc values on the flanging quality were analyzed, where Rf was defined as the ratio of the die fillet size to the workpiece thickness t and Rcwas defined as the ratio of the clearance C to the workpiece thickness t. Also the effect of Rf and Rc on upsetting ratio Ru which was defined as the ratio of thickness before and after upsetting were studied. The finite element results were validated by experimental results. Also a 2mm thick flange without thinning and defects was gained in a reasonable range of Rc and a certain value of Rf.