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Materials Today: Proceedings 4 (2017) 9316–9326 www.materialstoday.com/proceedings

ICAAMM-2016

Effect of process parameters on deformation behavior of AA 5052

sheets in stretch flanging process
Yogesh Dewanga*, M.S. Horab, S.K. Panthic
a
Assistant Professor, Department of Mechanical Engineering,Lakshmi Narain College of Technology, Bhopal,462021, India
b
Professor, Department of Civil Engineering,Maulana Azad National Institute of Technology, Bhopal, 462003, India
c
Scientist,Computer Simulation & Design Centre,Advanced Materials Processes and Research Institute,Bhopal,462024, India

Abstract

Aluminum alloys are widely used in manufacturing of aircrafts and in automotive industry. In this paper aluminum alloy 5052 of
0.5 mm thickness was utilized to investigate deformation behavior in stretch flanging process. The effect of process parameters
such as initial flange length, punch-die clearance and blank-holding force were investigated using FE simulation and
experimentation. The results show that the circumferential strain and radial strain increases with increase in initial flange length
and blank-holding force and decreases with increase in punch-die clearance. Experimental investigations were also carried out to
validate FE simulation results. A very good agreement was obtained between FE simulation results and experimental in terms of
punch load and edge crack location and propagation.

© 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility of the Committee Members of International Conference on Advancements in
Aeromechanical Materials for Manufacturing (ICAAMM-2016).

Keywords: stretch flanging; finite element simulation; punch-die clearance; initial flange length; blank-holding force; edge crack.

* Corresponding author. Tel.:+91-0755-2457105; fax: +91-0755-2457042.

E-mail address:[email protected]

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility ofthe Committee Members of International Conference on Advancements in Aeromechanical
Materials for Manufacturing (ICAAMM-2016).
 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326 9317

1. Introduction

Flanging is one of the important sheet metal forming processes which is applied in automobile industry.
Flanging is a sheet metal bending operation in which sheet is bent usually to 900 for providing a smooth
rounded edge, higher or strength to the edge of sheet-metal parts. It is also used for making hidden joints and
assembly of automobile parts. Flanging can be classified on the basis of deformation features into two major types
as shrink and stretch flanging. In shrink flanging, the curvature of flange is convex and metal is in compression in
circumferential direction. The arc length of final flange is smaller than arc length of original element. The
compression is greatest at the top of flange and least at die profile radius. In stretch flanging, the curvature of flange
is opposite to shrink flanging, i.e. concave and sheet metal undergoes tension in circumferential direction. The
tension is greatest at top of flange resulting in increase in the length of arc.
The feasibility of any sheet metal forming process depends upon various processes, geometric as well as
material parameters. To obtain defects free products different parameters need to be optimized. Different types of
failure like necking, wrinkling and fracture are involved in sheet metal forming processes. With the growth and
development of commercially available FEM software it is become easier to predict these types of defects. Finite
element simulation is an accurate and faster method for prediction of failure in sheet metal forming processes
because it captures realistic phenomena with less cost and time involved.
Researchers in past carried out work in the area of the failure analysis in sheet metal forming processes
using finite element simulation. Brunet et al. [1] used a gurson-tvergaard ductile damage based model for prediction
of necking and fracture for anisotropic sheet metals. Teixeira et al. [2] coupled Hill’s orthotropic plasticity criterion
with Lemaitre’s ductile damage evolution law for prediction of ductile fracture in sheet metal forming processes.
In deep drawing process, usually two types of failure modes namely fracture and wrinkling were
encountered. Li et al. [3] applied modified Mohr-Coulomb fracture criterion in the deep drawing of AHSS using
both circular and square punch for prediction of shear induced fracture in terms of crack initiation, propagation and
location of cracks. Wu et al. [4] found that that low blank-holding force will give rise to wrinkling while increase in
blank-holding force will lead to fracture during deep drawing of sheet metal with nickel. Nguyen et al. [5] predicted
wrinkling and fracture in deep drawing of SPCC material by using forming limit diagram ductile fracture criterion.
On the other hand, in case of flanging process the major type of defects were necking, fracture and
wrinkling. The major types of flanging are straight, stretch, shrink and hole-flanging in which studies were carried
out. Kacem et al. [6] predicted necking, damage, fracture and limit of flanging using a macroscopic ductile fracture
criterion by taking into account the triaxiality of material in hole-flanging of AA 1050-H-14 and AA-6061.In
another type of flanging process i.e., shrink flanging wrinkling was observed as failure. Wang et al. [7] predicted
wrinkling by using energy approach based on stress-based criterion.
Some studies were also carried out in the domain of flanging process in order to study the effect of various
parameters on formability of flange using various theoretical, experimental and FEM based approaches. Hu et al. [8]
proposed analytical models for introfelxion/stretch and outcurve/shrink flange which takes into account the effect of
planar anisotropy in flanging process for prediction of blank’s trim line. Dudra and Shah [9] developed analytical
model for development of trimline for axisymmetric case and utilized FEM method for non-axisymmetric case for
prediction of trimline and peak strain. Bao and Huh [10] implemented one-step analysis in trimming die design for
effective design procedure. Li et al. [11] used an equivalent 2D FEM program for parametric study in stretch
flanging of V-shaped blanks. Wang et al. [12] utilized an elastic-plastic FEM program in order to study the effect of
various materials and process parameters on the formability of flange in stretch flanging of V-shaped blanks. Yeh et
al. [13] determined optimum blank shape by using forward-inverse prediction scheme which integrates explicit
dynamic FEM, true strain method and adaptive-network-based fuzzy inference system in stretch flanging.
In stretch flanging, the predominant mode of failure was along edge as fracture and localized necking.
Wang et al. [14] proposed localized necking for stretch flanging of AKDQ steels based on modification of Hill’s
instability criterion by taking into account the effect of strain-hardening and plastic anisotropy. Asnafi [15] found
that fracture limit was obtained by increasing plastic strain ratio, strain hardening exponent and uniform strain in
stretch flanging through fluid forming of aluminum alloys.Worswick and Finn [16] found through numerical
simulation that strain predictions were more accurate with Barlat-89 and Hill-48 yield criteria than von-Mises yield
criteria in stretch flange forming. Feng et al. [17] recommended small flange height and small ratio of straight side
length to the curved range radius in stretch curved flanging in order to avoid fracture at edge of flange.
9318 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326

In finite element simulation of stretch flange forming the concept of continuum mechanics was employed
by various researchers for prediction of failure prediction of failure. Chen et al. [18] employed a multi-scale finite
element damage percolation model to simulate stretch flange forming of AA 5182 and AA 5754. Butcher et al. [19]
used a lower bound damage–based model for prediction of radial and circumferential cracks in stretch z-flanges of
AA 5182. Simha et al. [20] utilized continuum mechanics based approach for prediction of radial and
circumferential crack in AA 5182 stretch flanges on the basis of extended stress-based forming limit curve. Dewang
et al. [21] reviewed the different failure criterions for prediction of failure in stretch flanging process. Dewang et al.
[22] found that circumferential strain and edge cracking increases with increase in coefficient of friction, initial
flange length, die profile radius while decreases with increase in punch-die clearance and punch profile radius in
stretch flange forming. The objective of present work is to investigate the deformation behavior of AA 5052 of 0.5
mm thickness in stretch flanging process considering the effect of process parameters such as punch-die clearance,
initial flange length and blank-holding force through FEM simulation and experimentation. The results of FE
simulation are presented in terms of circumferential strain, radial strain, edge crack location and propagation and
maximum punch load during stretch flanging.

2. Mechanical Properties of material

The mechanical properties of aluminum alloy 5052 sheet was evaluated as per ASTM standard (ASTM E8/E8M–
11)[22].The tensile specimens are tested on a computerized universal testing machine INSTRON at a strain rate of
0.16667 s-1 along the rolling direction at room temperature. The following true stress-true strain curve is obtained as
shown in Figure 1. Table 1 and table 2 show the tested chemical composition and mechanical properties of AA 5052
of thickness 0.5mm.
Table 1. Chemical composition of AA 5052[22]
Element Si Fe Mg Mn Cu Cr Ni Zn Al
Wt.% 0.1224 0.1964 2.418 0.07688 0.03618 0.1688 0.00398 0.04454 95.70

Table 2. Mechanical Properties of AA 5052 [22]

Mechanical Property Material AA 5052

Mass density 2680 kg/m3

Young’s Modulus 70.3 GPa
Poisson’s ratio 0.33

Fig.1. True stress-true strain curve for AA 5052 [22]

 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326 9319

3. Finite Element Modeling & Simulation

In the current research work, FE simulation of stretch flanging process is carried out using FEM based
software ABAQUS/Explicit [23]. Figure 2 shows the FE model of non-axisymmetric stretch flanging process.
Rectangular blank of 120 mm × 25 mm × 0.5 mm size is used. Die, punch and blank-holder are considered as rigid
body tools and are modelled with 4-noded bilinear quadrilateral discrete rigid 3D (R3D4) elements. The rectangular
sheet metal blank is discretized by using 3D solid (C3D8R) elements. Isotropic hardening rule with ductile damage
parameter is considered during FE simulation. Prediction of failure is demonstrated by defining ductile damage
initiation criteria as a function of equivalent plastic strain. The initiation and propagation of edge cracks in the
flange is defined using by damage evolution feature with element deletion technique. Crack initiation in the stretch
flange is observed when ductile damage parameter (D) becomes unity. The whole process of simulation of stretch
flanging process is carried out in number of small steps.

Fig.2. Finite element model of non-axisymmetric stretch flanging process [23]

4. Experimental work of stretch flanging process

In order to validate the results of FE simulations, experiments are performed on a small punch testing
machine equipped with a load cell of capacity 1 KN. The experimental tools and workpiece used in this study are
shown in Figure 3. The experimental tool consists of punch, die and blank-holder. A rectangular blank of 120 mm ×
25 mm × 0.5 mm size are used in this study as work piece material. Non-axisymmetric stretch flanging process is
realized experimentally by clamping the work piece between blank-holder and die by using four bolts M10. A
constant blank-holding force is maintained during flanging by tightening the bolts with help of mechanical torque
wrench. A constant speed of 10 mm/min is given to the punch head during stretch flanging experiments. The results
of punch displacements and punch load and of the load cell are continuously stored in a data acquisition system.
9320 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326

Fig.3. Experimental tool and work piece [23]

5. Results & Discussion

The following section describes the effect of constant blank holding forces with low intensity on
circumferential strain and radial strain. Besides this, other FE simulation results are also presented for radius of die
of 20 mm for different process parameters in terms of the maximum circumferential strain and the maximum radial
strain. The intensity of blank holding forces which is utilized lies in the range of 80 N to 160 N (in a step of 20 N).

5.1 Effect of low intensity constant blank holding forces on circumferential strain

The circumferential strain is one the important parameters which affects the formability of stretch flange.
Figure 4 shows that the circumferential strain distribution along die profile radius from end of the sheet up to sheet
center. It is clear from Figure 6 that circumferential strain reaches the maximum value at corner end of flange, while
it decreases gradually up to a position near to the corner edge and then becomes more or less constant up to sheet
center at the lowest values of strain. A similar trend is found for all cases of constant blank holding forces. It is
important to note that circumferential strain increases by nearly 64 % with increase in blank holding force from 80
N to 160 N at edge of stretch flange. The circumferential strain at the edge is found to be maximum for each blank
holding force as well as circumferential strain at the corner of the stretch flange is increasing with increase in blank
holding force because with increase in blank holding force, the blank will experience greater contact with interacting
surfaces and as a result of which circumferential strain increases due to increment in coefficient of friction.
 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326 9321

Fig.4 Effect of blank holding force on circumferential strain distribution

Figure 5 shows the different contour plots of circumferential strain developed in the stretch flange on
application of low intensity constant blank holding forces. It is found that circumferential strain increases with
increase in blank holding forces. The edge crack is absent in case of three blank holding forces of intensity 80 N,
100N and 120 N. On the other hand, edge cracks start to appear on application of blank holding force of 140 N and
it further propagates more in case of blank holding force of 160 N. This indicates that blank holding force has a
major role in forming of stretch flange which is governed by another vital parameter i.e., circumferential strain and
excess of which will lead to edge cracks. The coefficient of friction also plays an important role as increase in blank
holding force the interacting coefficient of friction increases which reduce the possibilities of slipping of blank and
it also increases the chances of edge cracking with increment of circumferential strain too.

(a) (b) (c)

(d) (e)
Fig.5 Contour plots for circumferential strain at blank holding force of (a) 80N (b) 100 N (c) 120 N (d) 140 N (e) 160 N
9322 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326

5.2 Effect of blank holding force on maximum circumferential strain (initial flange length-basis)
Figure 6 shows the effect of blank holding force on the maximum circumferential strain at a punch- die
clearance of 1mm for three different initial flange lengths. It is found that the maximum circumferential strain
increases by nearly 17 % at the maximum blank holding force of 160 N with increase in initial flange length from 20
mm to 40 mm. The increment in circumferential strain with increase in initial flange length and blank holding force
increases the degree of deformation and holding capacity of the blank between the blank-holder. In addition to this,
the coefficient of friction plays a major role in increment of circumferential strain with increase in initial flange
length and blank holding force.

Fig.6 Effect of blank holding force on the maximum circumferential strain (c = 1 mm)

5.3 Effect of blank holding force on maximum circumferential strain (punch-die clearance base)
Circumferential strain increases non- linearly with increase in blank holding force, as shown in Figure 7,
for an initial flange length of 30 mm and a punch die clearance from 1 mm to 3 mm. The maximum circumferential
strain decreases by nearly 22% with increase in punch die clearance from 1 to 3 mm at a peak blank holding force of
160 N. The increment in punch-die clearance decreases the coefficient of friction, while increment in blank holding
increases the coefficient of friction among the interacting surfaces. Therefore the highest circumferential strain is
obtained for highest blank holding force and least punch-die clearance, which also signifies the role of coefficient of
friction in formation of stretch flange.

Fig.7 Effect of blank holding force on the maximum circumferential strain (L = 30 mm)

5.4 Effect of blank holding force on radial strain (initial flange length base)
Figure 8 shows that the maximum radial strain increases with increase in blank holding force from 80 N to
160 N, at a clearance of 1 mm for the three different initial flange lengths. It is found that the maximum radial strain
for initial flange length of 40 mm becomes nearly double that of the maximum radial strain for initial flange length
of 20 mm, at a peak blank holding force of 160 N. The increment in radial strain is occurring in the stretch flange
because the higher will be the initial flange length and blank holding force the greater will be the degree of
deformation, which increases the coefficient of friction and as a result of which the radial strain increases.
 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326 9323

Fig.8 Effect of blank holding force on radial strain (c = 1mm)

5.5 Effect of blank holding force on radial strain (punch-die clearance base)
Figure 9 shows the variation of maximum radial strain with blank holding force for five different punch-die
clearances at an initial flange length of 30 mm and width of sheet of 20 mm at die radius of 20 mm. It is found that
the maximum radial strain increases nonlinearly with increase in blank holding force for all the five punch-die
clearances. It is also found that the maximum radial strain is obtained for the minimum punch die clearance while
the minimum radial strain is obtained for the greatest punch die clearance. Besides this, it is found that there is a
decrease in the maximum radial strain by nearly 23% when punch die clearance varies from 1.5 mm to 3 mm. The
maximum radial strain at punch die clearance of 3 mm becomes nearly 0.14 times to that obtained for 1 mm punch-
die clearance. The increment in radial strain occurring in the stretch flange is occurring due to the increment in blank
holding force and in decrement of punch die clearance. The higher will be punch-die clearance the blank will
experience lesser coefficient of friction. Therefore the maximum radial strain is obtained for least punch-die
clearance and highest blank holding force.

Fig.9 Effect of blank holding force on maximum radial strain (L=30 mm)

Increment in maximum radial strain occurring in the stretch flange with increase in blank holding force and
different initial flange lengths is basically due to the increment in greater degree of deformation. Both blank holding
force increases the possibilities of greater contact and again coefficient of friction plays important role in occurrence
of greater radial strain in the flange. Besides, this the maximum radial strain also increases with increase in initial
flange length. The highest radial strain is obtained for the highest blank holding force, highest initial flange and least
punch-die clearance.
9324 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326

5.6 Effect of blank-holding force on punch load and forming kinematics

In this section, five different constant blank holding forces are applied on the blank holder. It is clear from
Figure 10 that for all the five cases of constant blank holding forces, the punch load increases in order to start
bending the sheet from unbent position and reaches to a maximum value. Further the punch load decreases due to
crack initiation and crack length increases and finally punch load decreases to attain a constant lowest value. It is
important to note that punch load increases by nearly 14 % with increase in blank holding force from 80 N to 160 N.
The maximum punch load is evaluated through numerical simulation of stretch flanging process under the influence
of blank holding forces in combination with initial flange length and punch die clearance. The reason for increment
in punch load with increase in blank holding force is due to greater contact of blank with the interacting surfaces and
blank holding force will keep the sheet in contact for greater deformation of blank. Again coefficient of friction
plays an important role in forming of flange as with increment in blank holding force, the chance of slipping of
blank also decreases. Therefore higher will be the blank holding force, higher punch load will be required for
formation of flange through punch over a given range of punch displacement.

Fig.10 Punch load versus punch displacement for constant blank holding forces

6. Validation of results

6.1 Comparison of edge crack location and propagation (punch-die clearance basis)

Fig.11 shows the comparison of edge crack location and propagation between FE simulation and
experimentation on increment in punch-die clearance. It is found that edge cracking decreases with increase in
punch-die clearance. This is occurring due to the fact that the circumferential strain decreases with increase in
punch-die clearance which in turn actually decreases the edge cracking in the stretch flange. A very good agreement
is found between experimental results and FE simulation results in terms of edge crack location and propagation.

(a) c = 1 mm (b) c = 2 mm (c) c = 3 mm (d) c = 1 mm (e) c = 2 mm (f) c = 3 mm

Fig.11. Comparison of edge crack location for different punch-die clearance between experimental (a-c) and FEM simulation (d-f)
 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326 9325

6.2 Comparison of edge crack location and propagation (initial flange length basis)

Fig.12 shows the comparison of edge crack location and propagation between FE simulation and
experimentation on increment in punch-die clearance. It is found that edge cracking increases with increase in initial
flange length. This is occurring due to the fact that the circumferential strain increases with increase in initial flange
length as greater flange length is available for deformation in flange, which in turn actually increases the edge
cracking in the stretch flange. A very good agreement is found between experimental results and FE simulation
results in terms of edge crack location and propagation.

(a) FEM (L= 40 mm) (b) Experimental (L= 40 mm) (c) FEM (L= 40 mm) (d) Experimental (L= 40 mm)
Fig.12 (a-d) Comparison of edge crack location for different initial flange length between FE simulation and experiments

6.3 Comparison of edge crack location and propagation (blank holding force basis)

Another case used for validation is shown in Figure.13 in which different blank holding forces are applied
by introducing sheet metal blanks for providing gaps between the work-piece and blank holder in the range of D = 1
mm to 3 mm (D = 1mm, 2mm ,3 mm). It is found, both from simulation and experimentation that crack length
decreases with increase in gap between blank holder and sheet metal blank because of decrease in circumferential
strain. It is observed that for D = 1 mm edge crack appears both in simulation and experiments. It is also pertinent to
point out that no edge crack appears on increasing the gap (D) further from 1.5 mm to 3 mm, both in simulation and
experiments. It is noticed that more and more material accumulates along die profile radius on increasing the gap
between sheet metal blank and blank holder which can be seen both in simulation and experimental results as
bulging of sheet metal along die profile radius due to decrement in blank holding force. Bulging is found to increase
with increase in gap between sheet metal blank and blank holder due to the decrease in blank holding force on sheet
metal blank. Very good agreement is again obtained between the results obtained through FE simulation and
experiments.

(a) D = 1 mm (b) D = 2 mm (c) D = 3 mm (d) D = 1 mm (e) D = 2 mm (f) D = 3 mm

Fig. 13 Comparison of edge crack location and propagation for different blank holding forces between FE simulation (a-c) and experimental (d-f)
9326 Yogesh Dewang et al / Materials Today: Proceedings 4 (2017) 9316–9326

7. Conclusions
It can be concluded from this study of stretch flanging process that blank holding force, punch die-clearance and
initial flange length are found to be important process parameters which greatly influence strain distribution and
edge crack. It is found that edge crack and circumferential strain increases with increase in blank holding force and
initial flange length while it decreases with punch-die clearance. Therefore, FEM simulation is quite helpful in better
designing of stretch flanging process to obtained defect free products.

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