LAUSR

Abstract Nowadays, lots of flanging parts formed with the sheet metal have been widely used in the automotive industry. The fineblanked-extrusion flanging process can be used to fabricate the sheet metal flanging parts with high surface quality, high dimensional accuracy and production efficiency when compared with the conventional hole flanging process. In this paper, the process parameters were mathematically analyzed firstly, and the relationship between the punch displacements in fineblanking process H1 and in extrusion process H4 was presented. Then, a finite element model was created and verified by comparing with the experimental result. Using the valid finite element model, the forming load, metal flow, and damage distributions during the forming process were comprehensively analyzed, and the relationship between the workpiece thickness, flange wall thickness and the flange height has been revealed. Based on these simulation results, the deformation mechanism of the fineblanked-extrusion flanging process was revealed.