A COMPARATIVE ANALYSIS STUDY OF HOLE FLANGING BY INCREMENTAL SHEET FORMING PROCESS OF AA1060 AND DC01 SHEET METALS

Incremental sheet forming (ISF) of hole flanged parts is recognised as an advanced sheet metal forming process with a high level of economic potential rewarding for small batch production of conical or cylindrical flanges for sheet blank with initial hole diameter. The current work investigates the formability of AA1060 aluminium alloy and DCO1 carbon steel sheet metals throughout the hole flanging process by using the incremental forming technique. The process is explored by employing experimental analysis and compared with the numerical simulation results. A three-dimensional finite element model was developed to perform the numerical analysis on the incremental hole flanging process of truncated cone product by using Commercial ANSYS V.18 (Workbench LS-DYNA model) software to evaluate the effect of different pre-cut hole diameters on the quality of the final product. An elastic-plastic behaviour according to Cowper Symonds power-law hardening, assuming isotropic properties was used to simulate the plasticity behaviour of AA1060 and DCO1 sheet materials during the hole flanging incremental forming process. The response of different parameters such as final hole diameter, forming depth, forming force, thickness distribution, thinning ratio, fracture behaviour, Von-Mises stress and effective plastic strain had been analysed numerically and experimentally for the verification of the results. The observations of this paper reveal that the DCO1 carbon steel exhibit better results of response process parameters in comparison with AA1060 aluminium alloy at different initial hole diameters and the improvements in the results of DCO1 as compared to AA1060 were as follow: 2.34% for the final hole diameter, 14.58% for the minimum thickness and 3.7% for the effective plastic strain.