Abstract
The manufacturing of necks on the sheet metal parts using conventional hole-flanging process in small series production is sometimes too expensive or even impossible due to the complexity of the product. For these reasons, a modern manufacturing concept called the “backward incremental hole-flanging process” is proposed. It enables producing necks on the final products that can be very complex or even closed with minimal expense. Special attention is dedicated to researching technological particularities and limitations according to industrial requirements. Due to numerous input factors having various levels of influence, empirical modelling was selected with the aim of ensuring better prediction of results. It enables predicting the impact of each particular input parameter and their iterations on the selected output variables. Results show that forming tool diameter, and horizontal and vertical step sizes have the greatest influence on the process. Moreover, the appropriate selection of process parameters results on a higher forming limit ratio and consequently, on larger necks achieved without cracks in comparison to the conventional hole-flanging process. The reason could be found in local incremental deformation of the sheet metal and a more suitable stress state.
Highlights
In tool making companies working on automotive sheet metal parts, the definition of the forming procedure is one of the most important tasks, especially for producing prototypes or parts in small quantities, e.g. products for crash tests
Multi-collinearity is indicated by the variance inflation factor (VIF), which quantitatively expresses the variances of regression coefficients regarding to the orthogonality of the regression coefficient matrix
The results show that the regression model of neck thinning depends mainly on the forming tool diameter and vertical step size
Summary
In tool making companies working on automotive sheet metal parts, the definition of the forming procedure is one of the most important tasks, especially for producing prototypes or parts in small quantities, e.g. products for crash tests. Some parts can be very complex; their production requires the application of numerous forming steps. In such cases, the forming tools are very large and made of various subsystems. The forming tools are very large and made of various subsystems A conventional technology called the hole-flanging process is applied to produce necks. This technology drastically increases the complexity of the tool, tool costs and product costs
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