Process optimization in stamping—a case study for flanging a clutch hub from steel plate

A large variety of bending and flanging processes is required in stamping for automotive applications. Traditionally the design process for bending and flanging tools is based on trial-and-error and on the skill of experienced die-makers. This approach results in high development cost and long lead-times. Computer simulations are excellent tools to predict and evaluate the tool and process design. In the present case study, the deformation could be predicted by finite-element method (FEM) techniques. From simulations, it was observed that the present process failed to obtain the dimensional requirements while maintaining sufficient strength (no fracture) of the part. A number of design modifications have been evaluated to determine the optimum parameters for the selected process conditions. The results have been validated with observations of the actual process.