Experimental investigation of steel sheet using incremental hole flanging Process

Incremental Hole-Flanging (IHF) provides substantial benefits for low-volume manufacturing and expedited prototyping of conical and vertical flanges in sheet metal components. Comprehending the deformation mechanics and failure processes of IHF is crucial for attaining defect-free forming. This research conducted multistage conical hole-flanging tests using Extra Deep Drawing (EDD) steel sheets including pre-cut centre holes of 40 mm and 70 mm in diameter. A CNC milling machine was used to create conical flanges with wall angles varying from 60° to 90°, in 10° increments. Experimental findings indicated that fracture transpired in the specimen with a 40 mm pre-cut hole at an 80° flange angle, however no fracture was detected in the 70 mm specimen, even at 90°. The inquiry also examines differences in flange depth, forming forces, and surface roughness to clarify material deformation and failure behaviour.