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<p>The research on multi-stage Incremental hole flanging (IHF) has proved the feasibility of forming hole flanges through incremental sheet forming (ISF) on several shapes and different materials. Multi-stage IHF strategies enhance process capabilities and structural accuracy; however, they are time-consuming due to the number of forming stages. To a certain extent, the production time constraint can be handled by employing single-stage IHF strategies. However, limited attention has been given to them in literature. To explore the capabilities of the single-stage IHF process, this research investigates two different single-stage IHF strategies. These strategies differ in their starting positions and subsequent toolpaths. In the first strategy, forming begins from an offset to the pre-cut hole, following an outside-in toolpath. In contrast, the other strategy initiates flange formation directly from the pre-cut hole edge, with the tool moving in an inside-out toolpath. In this work, a hole flange on a 1&#xa0;mm thick AA1050 sheet with a pre-cut hole diameter of 50&#xa0;mm is performed experimentally. Experimental trials reveal two failure characteristics while changing the offset distance. Comparatively, the successfully formed flanges show that the flange formation from the pre-cut hole edge yields a bigger flange diameter and reduced wall thinning. 3D finite element (FE) analysis supports the experimental results and is employed to investigate the deformation behavior during these IHF strategies. FE simulation results reveal that excessive meridional strain leads to failure due to thinning, while excessive circumferential strain causes failure at the flange edge.</p>

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Investigating the single-stage incremental hole flanging capabilities based on toolpath strategies

  • 期刊论文

  • 发表日期：

    2026年3月17日

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  • Abhay Kumar Dubey,
  • Harshal Y. Shahare,
  • R. Seetharam,
  • Yanle Li,
  • Denis Pustovoytov,
  • Alexander Pesin,
  • Puneet Tandon

摘要

The research on multi-stage Incremental hole flanging (IHF) has proved the feasibility of forming hole flanges through incremental sheet forming (ISF) on several shapes and different materials. Multi-stage IHF strategies enhance process capabilities and structural accuracy; however, they are time-consuming due to the number of forming stages. To a certain extent, the production time constraint can be handled by employing single-stage IHF strategies. However, limited attention has been given to them in literature. To explore the capabilities of the single-stage IHF process, this research investigates two different single-stage IHF strategies. These strategies differ in their starting positions and subsequent toolpaths. In the first strategy, forming begins from an offset to the pre-cut hole, following an outside-in toolpath. In contrast, the other strategy initiates flange formation directly from the pre-cut hole edge, with the tool moving in an inside-out toolpath. In this work, a hole flange on a 1 mm thick AA1050 sheet with a pre-cut hole diameter of 50 mm is performed experimentally. Experimental trials reveal two failure characteristics while changing the offset distance. Comparatively, the successfully formed flanges show that the flange formation from the pre-cut hole edge yields a bigger flange diameter and reduced wall thinning. 3D finite element (FE) analysis supports the experimental results and is employed to investigate the deformation behavior during these IHF strategies. FE simulation results reveal that excessive meridional strain leads to failure due to thinning, while excessive circumferential strain causes failure at the flange edge.