Experimental Investigation and Finite Element Simulation of Hole-Flanging Process by Single Point Incremental Forming

Incremental forming method with lower cost and more flexibility can be a suitable alternative for traditional methods of the hole-flanging. In this study, the possibility of square hole-flanging of AL1050 aluminum sheet using incremental forming method has been investigated and the quality of the pyramid flange has been compared with conical flange. The final shape of the flange is defined so that wall angle increases with raising height. The process simulation was performed using Abaqus software and an experimental test was done to validate the simulation results. After performing the experimental tests, flange features such as the final size of the hole, flange height, and wall thickness were measured. The results showed that at the created flange around the circular hole, there is less spring back and more dimensional accuracy, however, it can be flanged a square hole by incremental approach with consideration of the height and hole size. The dimensional measurements showed that the final size of the hole will increase after the hole-flanging. By investigation of the various holes, it was found that in the larger initial hole, increasing the hole size after the flanging will be lower.