Abstract
The main objective of this study is to characterize the effects of the pre-hole geometry on the countersinking process. The final shape of the countersunk hole and the punch load were investigated. A finite element model was developed using ABAQUS/Standard. A configuration with maintained blank-holder was used for this study. The adopted model was performed with an elastoplastic behavior and isotropic hardening rule for the workpiece. In this study, an approach based on the definitive screening design (DSD) was performed to perform a parametric study and a statistical analysis to investigate the effects of the geometrical parameters of the pre-hole and their interactions on the countersinking process. The evolution plot of the parameters of the final countersunk hole shape, during the process, was an additional tool to better understand the obtained results. It was concluded that the inner radius of the pre-hole had the most important impact on this final shape. In addition, it was found that the punch load was more affected by the fillet radius of the pre-hole than the other parameters. Concerning the thickness of the workpiece, it had the lowest influence on the process. The experiments were carried out and the obtained results were in good agreement with the numerical ones.
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