Deformation mechanics and failure mode in stretch and shrink flanging by double-sided incremental forming

Huan Zhang; Zixuan Zhang; Huaqing Ren; Jian Cao; Jun Chen

doi:10.1016/j.ijmecsci.2018.06.002

Deformation mechanics and failure mode in stretch and shrink flanging by double-sided incremental forming

Huan Zhang, Zixuan Zhang, Huaqing Ren, Jian Cao, Jun Chen^*

^*Corresponding author for this work

Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

31 Scopus citations

Abstract

Incremental sheet metal flanging is efficient and cost-effective in prototyping and low-volume production. However, how the sheet metal fails and how the overall formability is enhanced during incremental sheet flanging are still not well understood. This study attempts to provide an updated level of understanding for the deformation mechanics in fabricating a clover hole-flange with complex in-plane curvatures by double-sided incremental forming. Compared with traditional flanging methods, higher formability has been achieved for both stretch flanging and shrink flanging on a single part. Additionally, numerical simulation is conducted complementarily to reveal the strain evolution, based on which failure modes and reasons are analyzed. Moreover, DMV (Donell–Mushtari–Vlasov) equations are employed to analytically study the shrink flanging process. The investigations lead to the conclusions that meridional tension has positive effect in improving the formability during shrink flanging, while an adverse effect is found in the formability during stretch flanging.

Original language	English (US)
Pages (from-to)	216-222
Number of pages	7
Journal	International Journal of Mechanical Sciences
Volume	144
DOIs	https://doi.org/10.1016/j.ijmecsci.2018.06.002
State	Published - Aug 2018

Funding

The authors are grateful for the financial support from the National Natural Science Foundation of China through grant U1737210 . This research was supported in part by the Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy administered by the Oak Ridge Institute for Science and Education (ORISE) for the DOE. ORISE is managed by Oak Ridge Associated Universities (ORAU) under DOE contract number DE-SC0014664 .

Keywords

Deformation mechanics
Double-sided incremental forming
Failure mode
Incremental flanging
Numerical simulation

ASJC Scopus subject areas

Condensed Matter Physics
Mechanics of Materials
Mechanical Engineering
Aerospace Engineering
Ocean Engineering
Applied Mathematics
General Materials Science
Civil and Structural Engineering

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10.1016/j.ijmecsci.2018.06.002

Cite this

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title = "Deformation mechanics and failure mode in stretch and shrink flanging by double-sided incremental forming",

abstract = "Incremental sheet metal flanging is efficient and cost-effective in prototyping and low-volume production. However, how the sheet metal fails and how the overall formability is enhanced during incremental sheet flanging are still not well understood. This study attempts to provide an updated level of understanding for the deformation mechanics in fabricating a clover hole-flange with complex in-plane curvatures by double-sided incremental forming. Compared with traditional flanging methods, higher formability has been achieved for both stretch flanging and shrink flanging on a single part. Additionally, numerical simulation is conducted complementarily to reveal the strain evolution, based on which failure modes and reasons are analyzed. Moreover, DMV (Donell–Mushtari–Vlasov) equations are employed to analytically study the shrink flanging process. The investigations lead to the conclusions that meridional tension has positive effect in improving the formability during shrink flanging, while an adverse effect is found in the formability during stretch flanging.",

keywords = "Deformation mechanics, Double-sided incremental forming, Failure mode, Incremental flanging, Numerical simulation",

author = "Huan Zhang and Zixuan Zhang and Huaqing Ren and Jian Cao and Jun Chen",

note = "Publisher Copyright: {\textcopyright} 2018 Elsevier Ltd",

year = "2018",

month = aug,

doi = "10.1016/j.ijmecsci.2018.06.002",

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AU - Zhang, Huan

AU - Zhang, Zixuan

AU - Ren, Huaqing

AU - Cao, Jian

AU - Chen, Jun

PY - 2018/8

Y1 - 2018/8

N2 - Incremental sheet metal flanging is efficient and cost-effective in prototyping and low-volume production. However, how the sheet metal fails and how the overall formability is enhanced during incremental sheet flanging are still not well understood. This study attempts to provide an updated level of understanding for the deformation mechanics in fabricating a clover hole-flange with complex in-plane curvatures by double-sided incremental forming. Compared with traditional flanging methods, higher formability has been achieved for both stretch flanging and shrink flanging on a single part. Additionally, numerical simulation is conducted complementarily to reveal the strain evolution, based on which failure modes and reasons are analyzed. Moreover, DMV (Donell–Mushtari–Vlasov) equations are employed to analytically study the shrink flanging process. The investigations lead to the conclusions that meridional tension has positive effect in improving the formability during shrink flanging, while an adverse effect is found in the formability during stretch flanging.

AB - Incremental sheet metal flanging is efficient and cost-effective in prototyping and low-volume production. However, how the sheet metal fails and how the overall formability is enhanced during incremental sheet flanging are still not well understood. This study attempts to provide an updated level of understanding for the deformation mechanics in fabricating a clover hole-flange with complex in-plane curvatures by double-sided incremental forming. Compared with traditional flanging methods, higher formability has been achieved for both stretch flanging and shrink flanging on a single part. Additionally, numerical simulation is conducted complementarily to reveal the strain evolution, based on which failure modes and reasons are analyzed. Moreover, DMV (Donell–Mushtari–Vlasov) equations are employed to analytically study the shrink flanging process. The investigations lead to the conclusions that meridional tension has positive effect in improving the formability during shrink flanging, while an adverse effect is found in the formability during stretch flanging.

KW - Deformation mechanics

KW - Double-sided incremental forming

KW - Failure mode

KW - Incremental flanging

KW - Numerical simulation

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Deformation mechanics and failure mode in stretch and shrink flanging by double-sided incremental forming

Abstract

Funding

Keywords

ASJC Scopus subject areas

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