Abstract
A new forming process, extrusion-burring process is proposed to produce the parts with a flange from a thick plate. The feature of the newly devised extrusion-burring process has been investigated in detail by FEM analysis and verified by a series of experiments with the aluminum plate. In the extrusion-burring process, a drawn cup is extruded by pushing its wall downwards and the extruded material flows into the flange portion. With increasing extrusion stroke the material of the flange portion gets thick and high. By increasing extrusion stroke, the flange height after burring process increase successfully. However, an excessive extrusion stroke results in the fracture at the base of the flange portion, because the burring process is very similar to the ironing process.
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