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<p>The article presents one of the ways to solve the problem of reducing flange wall thinning when flanging holes in sheet blanks. It is proposed to use a profiled sheet billet. The profile of the part of such a workpiece to be flared has a maximum thickness near the hole with a linear decrease in thickness to the original thickness at the diameter corresponding to the beginning of the radius of curvature of the flanging die. The modeling of the profiling of the AA2024 aluminum alloy billet using extrusion to obtain a hole and subsequent punching of the scrap and the processes of flanging the holes with flat, conical, and spherical punches was performed using the finite element method in the DEFORM 2D program. The elastic–plastic model of metal was used to determine the forces of deformation and removal of punches from flanges, as well as the final shape and dimensions of the flanges. The forces for profiling the billet and the dimensions of the profile on the billet were determined to ensure a constant wall thickness along the length of the flanges after flanging. The lowest flanging force for a profiled workpiece was obtained for a spherical punch. For such a punch, the flanging of a traditional sheet billet was modeled. The distributions of stress components in deformed workpieces at maximum flanging forces and deformation components in flanges were obtained. After flanging the profile billet, the flange has the same thickness along its length. The thickness of the flange end is significantly reduced after flanging a traditional billet. Experimental studies were conducted on flanging flanges in profiled and traditional billets. Experimental results on the forces of billet profiling and flanging and flange dimensions showed good agreement with the modeling data.</p>

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Increasing the geometric accuracy of flange walls when flanging holes by using profiled sheet metal workpieces

  • 期刊论文

  • 发表日期：

    2025年4月24日

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  • Stanislav Volodymyrovych Sytnyk,
  • Volodymyr Leonidovych Kaliuzhnyi,
  • Oleksandr Volodymyrovych Kaliuzhnyi,
  • Vadym Mykolayovych Hornostai

摘要

The article presents one of the ways to solve the problem of reducing flange wall thinning when flanging holes in sheet blanks. It is proposed to use a profiled sheet billet. The profile of the part of such a workpiece to be flared has a maximum thickness near the hole with a linear decrease in thickness to the original thickness at the diameter corresponding to the beginning of the radius of curvature of the flanging die. The modeling of the profiling of the AA2024 aluminum alloy billet using extrusion to obtain a hole and subsequent punching of the scrap and the processes of flanging the holes with flat, conical, and spherical punches was performed using the finite element method in the DEFORM 2D program. The elastic–plastic model of metal was used to determine the forces of deformation and removal of punches from flanges, as well as the final shape and dimensions of the flanges. The forces for profiling the billet and the dimensions of the profile on the billet were determined to ensure a constant wall thickness along the length of the flanges after flanging. The lowest flanging force for a profiled workpiece was obtained for a spherical punch. For such a punch, the flanging of a traditional sheet billet was modeled. The distributions of stress components in deformed workpieces at maximum flanging forces and deformation components in flanges were obtained. After flanging the profile billet, the flange has the same thickness along its length. The thickness of the flange end is significantly reduced after flanging a traditional billet. Experimental studies were conducted on flanging flanges in profiled and traditional billets. Experimental results on the forces of billet profiling and flanging and flange dimensions showed good agreement with the modeling data.