Abstract
In this work, the flanged hole is adopted as a potential solution to increase the number of formed threads in the case of sheet metal part. To achieve an adequate initial tap hole for tapping process, the final shape of the flanged hole was analyzed by 2D finite element (FE) simulations. An adequate range of the clearance j between the die and the punch of the hole-flanging process was identified for which formed threads are performed on a vertical flange with more substantial and uniform thickness as well as an important height. To ensure that the selected flange is free from fracture, 3D FE model was developed using Gurson-Tvergaard-Needleman coupled approach. Experiments were carried out in order to validate the numerical results and to analyze the geometry of formed threads performed on the selected flanged hole and the drilled hole.
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