A critical review on hole-flanging process

Hole flanging is a crucial manufacturing technique used in the automotive, aerospace, and plumbing industries for creating flanges. It involves heat transfer tube apertures, non-chafing tube openings, and tapped thread holes. Experimental methods include press working, incremental forming, electromagnetic forming, and paddle forming for experimental realization of hole flanging. Aluminum alloys are primarily used as workpiece material in hole flanging. Numerical modeling of hole flanging uses von-Mises yield criterion, isotropic circumstances, coulomb friction law, and elastic-plastic behavior in majority. The development of plastic strain and thickness distribution throughout the flange length is essential for defect-free hole flanges formation. The morphology of cracks during the hole flanging process is largely determined by circumferential tensile stresses, forming techniques, and other process parameters. Two commonly used methodologies for hole flanging process parameter optimization are the Taguchi approach and the FEM design optimization procedure utilized for hole flanging applications. Paddle forming offers improved formability, flexibility, lower tooling costs, and shorter process times as compared to others forming techniques of hole flanging. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.