Due to increasing legal requirements, lightweight construction and the use of high-strength aluminium alloys are becoming increasingly important. In order to further reduce weight, a wall thickness distribution in the component is applied which is adapted to the load case. The four-stage forming tool shown on the right was developed for this purpose. A maximum expansion ratio (punch diameter/pre-hole diameter) is aimed at within this process chain, so that after the third forming stage as much material as possible is available in the nozzle area for subsequent upsetting.
The aim of this work is the numerical and experimental investigation of the minimum usable hole diameter (stage 2) with simultaneous maximum possible nozzle/expansion (stage 3) under consideration of the temperature influence.
The exact work contents can be adapted in a non-binding discussion.