Experimental and numerical analysis of the flanging process by SPIF

Abstract

This paper analyses the flangeability of AA2024-T3 sheets using single point incremental forming (SPIF). With this purpose, a series of process parameters is considered including flange length and width, tool radius and spindle speed. An initial experimental campaign is carried out for the evaluation of the limiting strain states of the flanges within the material forming limit diagram (FLD). Numerical modelling through finite element analysis (FEA) is used in order to provide a better understanding of the sheets flangeability and forming conditions that either allow manufacturing or lead to failure in this process using concave dies. The capability of the SPIF process to improve formability is discussed.