In recent decades, the use of aluminium alloys is developed in the automotive industry with regard to the need for lightweight and anti-corrosion components, one of which is AA7075 Al alloy. In this study, the multi-step deep drawing process of AA7075 aluminium sheets under various blank holder forces is investigated through a numerical simulation and is then validated with experimental results. Simulations were conducted by ABAQUS finite element software, and the influences of the blank holder force on the wrinkling height, rupture occurrence and thickness distribution of the sheet were studied. The optimum amount of blank holder force at each drawing step is determined so that the height of wrinkling, and the thinning percentage do not exceed the permissible value. Based on the results, the blank holder force magnitude should be considered descending during the four successive steps to achieve more uniform thickness distribution, and also the wrinkling height could be reduced by increasing the blank holder force in the analysed force range. The optimum amount of blank holder force in the four drawing steps was 28000, 2500, 1500 and 600 N, respectively. In general, the minimum thickness was created in the corner of the punch. The results also showed that an excessive increase in the blank holder force in order to eliminate the wrinkling caused the thinning percentage to increase. Finally, a good accordance between the experimental and numerical results was observed. Manuscript profile

In this study, hole-flanging of a dual-phase steel sheet is conducted using incremental forming approach. In this process, a hole with a certain diameter is pre-cut on a sheet. Then, this hole is transformed into a cylindrical flange shapes, by contacting the forming tool with the hole edges. During the process, the tool is moved in spiral paths. The parameters affecting the height and thickness distribution of the formed flange include axial step, radial step, and rotational speed of the tool. Results show that the axial step has the most significant effect on the process, among other parameters; when the axial step is tripled, the flange thickness increases by 19%. On the other hand, a decrease in the radial step decreases the flange edge thickness. When the radial step is tripled, the flange thickness increases by 8%, while the flange height decreases about 3%. Manuscript profile