Numerical analysis of flanging using tailored rubber pad forming on AA7075-O sheets

Abstract. The flanging of metal sheets is extensively used in the automotive and aeronautical industries to provide rigidity or support for subsequent assembly. Flanging by rubber pad forming is one of the most common processes for small and medium batch production. Flanges with non-linear bending lines are exposed to severe conditions that significantly hinder our comprehension of the geometrical, material, and process factors associated with flange formability (i.e., flangeability). This work presents a numerical study of the flanging process by a tailored rubber pad of hollow AA7075-O parts with continuous concave and convex flanges. The flangeability limits, the geometric capabilities of the forming process, and the deformation mechanisms of stretched and shrunk flanges as well as in the transition zone between them are analysed.