Abstract
The axisymmetric stretch flanging process is a common secondary operation in sheet metal stamping. The process is characterized by a uniaxial state of stress at the edge of the flange. An approximate analysis, based on the assumption that the state of stress throughout the flange is mainly uniaxial, is used to model the stretch flanging (second step) process. The approximation is derived from the total strain membrane theory of plasticity which incorporates strain hardening and normal anisotropy of the material. Under such conditions, flangeability is controlled by the tensile elongation of the metal and is limited by localized necking or fracture of the flanged edge. The analysis includes a stretching limit criterion to determine the flanging limit of the material. The influence of prestretching (first step) on flangeability is modeled using the membrane shell theory with axisymmetric deformation to solve the contact condition in stretch forming. Inputs to the model are a desired flange profile, material properties, and sheet thickness. The output includes the feasibility of the flanging operation, any requirements for prestretching and the size of the trim radius needed to successfully flange the profile. The model is verified by experimental results.
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