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Open AccessArticle

Optimization of Hole-Flanging by Single Point Incremental Forming in Two Stages

Department of Mechanical Engineering and Manufacturing, Universidad de Sevilla, Camino de los Descubrimientos s/n, 41092 Sevilla, Spain
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Materials 2018, 11(10), 2029; https://doi.org/10.3390/ma11102029
Received: 20 September 2018 / Revised: 12 October 2018 / Accepted: 17 October 2018 / Published: 18 October 2018
(This article belongs to the Special Issue Special Issue of the Manufacturing Engineering Society (MES))
Single point incremental forming (SPIF) has been demonstrated to accomplish current trends and requirements in industry. Recent studies have applied this technology to hole-flanging by performing different forming strategies using one or multiple stages. In this work, an optimization procedure is proposed to balance fabrication time and thickness distribution along the produced flange in a two-stage variant. A detailed analytical, numerical and experimental investigation is carried out to provide, evaluate and corroborate the optimal strategy. The methodology begins by analysing the single-stage process to understand the deformation and failure mechanisms. Accordingly, a parametric two-stage SPIF strategy is proposed and evaluated by an explicit Finite Element Analysis to find the optimal parameters. The study is focused on AA7075-O sheets with different pre-cut hole diameters and considering a variety of forming tool radii. The study exposes the relevant role of the tool radius in finding the optimal hole-flanging process by the proposed two-stage SPIF. View Full-Text
Keywords: sheet metal forming; flanging; hole-flanging; incremental sheet forming; Single Point Incremental Forming (SPIF); finite element analysis; thickness distribution sheet metal forming; flanging; hole-flanging; incremental sheet forming; Single Point Incremental Forming (SPIF); finite element analysis; thickness distribution
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Morales-Palma, D.; Borrego, M.; Martínez-Donaire, A.J.; Centeno, G.; Vallellano, C. Optimization of Hole-Flanging by Single Point Incremental Forming in Two Stages. Materials 2018, 11, 2029.

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