Increasing of Stretch Formability on Hole-flanging Parts of Aluminum Alloys by Smooth Sheared Surface
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Abstract
Aluminum alloy is a lightweight material that fractures often occur during stretch forming, especially in the hole-flanging parts. However, the stretch formability of aluminum alloy increased by improving a smooth-sheared surface. The resistance of materials to edge fracture in complex shape forming is typically measured using the hole expansion ratio (HER). This paper presents the concave piercing punch design to increase smooth sheared surface which induces the increasing stretch formability of aluminum alloy. The effect of a smooth-sheared surface on stretch formability was examined via a hole expansion test (HET). The aluminum alloy grade AA1100, and AA5052 of 1.2 mm of thickness with three levels of clearance 5%t, 10%t, and 15%t were used in the experiments. The HER of aluminum alloy is influenced by a smooth sheared surface from conventional and concave piercing punch with varied clearances. In the experimental aspect, the clearance level and shape of the piercing punch, which are factors for the stretch formability of aluminum alloy, were observed by hole HER. The concave piercing punch design improves the hole expansion ratio more than a conventional piercing because a smooth sheared surface around the hole edge increases the hole expansion ratio.
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