Profiled Sheet Metal Blank for Flanging Flanges with Constant Wall Thickness

This article applies the finite element method and the DEFORM software to study the influence of the die rounding radius on the axisymmetric flanging of a profiled sheet blank made of aluminum AL-1100 COLD. A profiled blank with a part with an increased thickness to be flanged is obtained by forming a hole by extrusion by punching a bridge. It has the most significant thickness near the hole, with a subsequent linear decrease to the original thickness. The elastic-plastic model of metal was used for modeling. To compare the results, we calculated the flanging of a traditional blank. The dependence of the forces of flanging and punch removal on their displacement was determined. Increasing the radius of the die leads to a decrease in the flanging forces. The effort of punch removal for a traditional workpiece does not depend on the die radius, and for a profiled workpiece, it decreases with an increase in the die radius. The influence of the die radius on the stress state of deformed workpieces at the maximum flanging force and the final deformed state in the flanges was determined. The distribution and magnitude of stress components do not differ significantly when flanging conventional and profiled workpieces. The size of the matrix radius has a slight effect on the distribution of final deformation components in flanges after flanging. The shapes and sizes of flanges were determined after punches were removed from deformed blanks. The amount of thinning and curvature of the flange ends was determined for a traditional blank. The profiled blank provides flanges with a constant wall thickness along the length equal to the thickness of the original blank. Experimental studies have been carried out, which have shown good agreement with the modeling results in terms of flanging forces and flange dimensions.