FEM Simulation of Non-Axisymmetric Stretch Flange Forming of Aluminum Alloy 5052 Based on Shell Type Elements

Finite element simulation of stretch flanging process was carried out in order to investigate the effect of process parameters on maximum thinning (%) in stretch flanging process. Influences of initial flange length, punch die clearance, width of sheet metal blank and blank holding force were investigated on maximum thinning (%). Finite element simulation was done using FEM software package ABAQUS. Sheet metal blanks of AA 5052 were utilized for numerical simulation of stretch flanging process. Mesh convergence study was carried out to ascertain the accuracy of present FEM model. It is found that circumferential strain and shell thickness decreases with decrease in initial flange length and punch-die clearance while both decreases with increase in blank-holding force. Radial strain increases with decrease in initial flange length and punch-die clearance and with increment in blank-holding force and width of sheet. It is found that width of sheet metal blank and blank holding force have greater influence on maximum thinning (%) as compared to initial flange length and punch die clearance.