FEM SIMULATION OF NON-AXISYMMETRIC STRETCH

FLANGING PROCESS USING SHELL ELEMENTS

SELECTION OF INPUT SELECTION OF SELECTION OF OUTPUT

PARAMETERS AS: WORKPIECE AS: PARAMETERS AS:

i. Punch-die clearance ALUMINUM ALLOY 5052 i. Circumferential strain

ii. Initial flange length SHEETS OF 0.5 MM ii. Radial strain
iii. Width of blank THICKNESS iii. Flange thickness
iv. Blank holding force iv. Percentage thinning

400

True stress (MPa)

PREPARATION & TESTING
OF TENSILE SAMPLES AS 300
PER ASTM E8/E8M
200
100
0
-0.1 0 0.1 0.2
-100
True strain
SELECTION OF SHELL (S4R) ELEMENTS FOR MESHING OF BLANK & DEVELOPMENT OF FEM MODEL
& MESH SENSITIVITY ANALYSIS

BENDING OF BLANK INTO DIE & PERCNETAGE OF THINNING AS VITAL OUPTUT OF FEM ANALYSIS
 HIGHLIGHTS

 Finite element simulation of non-axisymmetric stretch flanging process is carried out to study the
deformation behavior of AA 5052 sheets.
 Two dimensional shell (S4R) elements are used for meshing of AA 5052 sheet.

 The circumferential strain and shell thickness decreases with decrease in initial flange length
while radial strain increases with decrease in initial flange length.

 The circumferential strain and shell thickness decreases, with decrease in punch-die clearance
whereas radial strain increases with decrease in punch-die clearance.

 The circumferential strain and shell thickness decreases with increase in blank-holding force
while radial strain increases with increase in blank-holding force.

 The radial strain increases with increase in width of sheet along free edge up to centre of the sheet
while circumferential strain decreases with increase in width of sheet.

 The maximum percentage of thinning increases with increase in initial flange length, blank-
holding force, width of sheet while it decreases with increase in punch-die clearance.

 Maximum thinning occurs when the blank is bending into die because as the blank is bending into
die, circumferential tensile stresses are generated along die profile radius, which are greatest at
the edge of sheet.