Composite Hole Flanging Process by Single Point Incremental Hot Forming for AZ31 Magnesium Alloy

AN Zhiguo; HU Xiandong; ZHANG Tao; TANG Yong; GAO Zhengyuan

doi:10.3969/j.issn.1674-6457.2026.06.010

PDF(13377 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 99-111. DOI: 10.3969/j.issn.1674-6457.2026.06.010

Light Alloy Forming

Composite Hole Flanging Process by Single Point Incremental Hot Forming for AZ31 Magnesium Alloy

AN Zhiguo, HU Xiandong, ZHANG Tao, TANG Yong, GAO Zhengyuan^*

Author information +

History +

Abstract

The work aims to investigate the effects of prefabricated hole diameter, feed rate, punch displacement, and temperature on the forming quality in the Single Point Incremental Forming (SPIF) process for composite hole deep-drawing with AZ31B magnesium alloy sheets as research objects. Finite element simulation software was used to numerically simulate the forming process of 2 mm thick AZ31B magnesium alloy sheets, and the effects of different process parameters on the minimum thickness and average deviation in the forming region were analyzed. The multi-factor response surface method was used to analyze the interaction effects of different process parameters on the forming quality of the part, leading to the identification of the optimal process parameters, which were then experimentally validated. Punch displacement was found to be inversely proportional to the minimum wall thickness and directly proportional to the average deviation. Forming temperature had a significant effect on part quality, with the minimum wall thickness increasing as the forming temperature rose, and the average deviation significantly decreasing above 250 ℃. The feed rate was inversely proportional to the minimum wall thickness, and the average deviation showed more significant variation at lower feed rates. The prefabricated hole diameter was directly proportional to the minimum wall thickness of the formed region, while inversely proportional to the average deviation. The simulation model for the Single Point Incremental Forming (SPIF) process demonstrates high accuracy. Using the optimized process parameters, both the minimum thickness of parts is 1.66 mm, with the average deviation controlled within 3%. The forming temperature, the punch displacement and the prefabricated hole diameter has significant effects on the forming quality.

Key words

AZ31B magnesium alloy / single point incremental forming / hot forming / composite process / sheet metal forming

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

AN Zhiguo, HU Xiandong, ZHANG Tao, TANG Yong, GAO Zhengyuan. Composite Hole Flanging Process by Single Point Incremental Hot Forming for AZ31 Magnesium Alloy[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 99-111 https://doi.org/10.3969/j.issn.1674-6457.2026.06.010

References

[1] 尚苗, 李言, 杨明顺, 等. 液压支撑单点渐进成形临界角研究[J]. 中国机械工程, 2024, 35(1): 181-189.
SHANG M, LI Y, YANG M S, et al.Study on Critical Angle in Single-Point Incremental Forming with Hydraulic Supporting[J]. China Mechanical Engineering, 2024, 35(1): 181-189.
[2] 高正源, 李沛豪, 李正芳, 等. 航天用铝合金渐进成形韧性断裂数值预测的研究进展[J]. 精密成形工程, 2025, 17(6): 129-142.
GAO Z Y, LI P H, LI Z F, et al.Investigation Progress on Numerical Prediction of Toughness Fracture in Incremental Forming of Aluminum Alloys for Aerospace Applications[J]. Journal of Netshape Forming Engineering, 2025, 17(6): 129-142.
[3] 张泽昊, 王进. 基于随动支撑的板料渐进成形数值模拟[J]. 精密成形工程, 2023, 15(10): 111-119.
ZHANG Z H, WANG J.Numerical Simulation of Incremental Sheet Forming Based on Follower Support[J]. Journal of Netshape Forming Engineering, 2023, 15(10): 111-119.
[4] 安治国, 田维杰, 门正兴, 等. 单点渐进成形工艺参数对正五边锥形件壁厚的影响[J]. 精密成形工程, 2023, 15(1): 41-50.
AN Z G, TIAN W J, MEN Z X, et al.Effects of Process Parameters on Wall Thickness of Regular Pentagonal Frustums by Single Point Incremental Forming[J]. Journal of Netshape Forming Engineering, 2023, 15(1): 41-50.
[5] LEONHARDT A, KURZ G, VICTORIA-HERNÁNDEZ J, et al. Experimental Study on Incremental Sheet Forming of Magnesium Alloy AZ31 with Hot Air Heating[J]. Procedia Manufacturing, 2018, 15: 1192-1199.
[6] AMBROGIO G, GAGLIARDI F.Temperature Variation during High Speed Incremental Forming on Different Lightweight Alloys[J]. The International Journal of Advanced Manufacturing Technology, 2015, 76(9): 1819-1825.
[7] KHAZAALI H, FERESHTEH-SANIEE F.A Comprehensive Experimental Investigation on the Influences of the Process Variables on Warm Incremental Forming of Ti-6Al-4V Titanium Alloy Using a Simple Technique[J]. The International Journal of Advanced Manufacturing Technology, 2016, 87(9): 2911-2923.
[8] HONARPISHEH M, ABDOLHOSEINI M J, AMINI S.Experimental and Numerical Investigation of the Hot Incremental Forming of Ti-6Al-4V Sheet Using Electrical Current[J]. The International Journal of Advanced Manufacturing Technology, 2016, 83(9): 2027-2037.
[9] BAO W K, CHU X R, LIN S X, et al.Experimental Investigation on Formability and Microstructure of AZ31B Alloy in Electropulse-Assisted Incremental Forming[J]. Materials & Design, 2015, 87: 632-639.
[10] GUPTA P, JESWIET J.Observations on Heat Generated in Single Point Incremental Forming[J]. Procedia Engineering, 2017, 183: 161-167.
[11] HUSSAIN G, VALAEI H, AL-GHAMDI K A, et al. Finite Element and Experimental Analyses of Cylindrical Hole Flanging in Incremental Forming[J]. Transactions of Nonferrous Metals Society of China, 2016, 26(9): 2419-2425.
[12] LI Y L, DANIEL W J T, MEEHAN P A. Deformation Analysis in Single-Point Incremental Forming through Finite Element Simulation[J]. The International Journal of Advanced Manufacturing Technology, 2017, 88(1): 255-267.
[13] AI S, LU B, CHEN J, et al.Evaluation of Deformation Stability and Fracture Mechanism in Incremental Sheet Forming[J]. International Journal of Mechanical Sciences, 2017, 124: 174-184.
[14] BEN S L, MARS J, WALI M, et al.Numerical Prediction of the Ductile Damage in Single Point Incremental Forming Process[J]. International Journal of Mechanical Sciences, 2017, 131: 546-558.
[15] KUMAR A, GULATI V, KUMAR P, et al.Forming Force in Incremental Sheet Forming: A Comparative Analysis of the State of the Art[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2019, 41(6): 251.
[16] JAGTAP R, KUMAR S.Incremental Sheet Forming: An Experimental Study on the Geometric Accuracy of Formed Parts[C]// Innovative Design, Analysis and Development Practices in Aerospace and Automotive Engineering (I-DAD 2018). Singapore: Springer, 2019: 83-89.
[17] MASHUDI I, FAKHRUDDIN M, HARDJITO A.Forming Parameters Effect Toward Flange Height on Single-Step Incremental Backward Hole Flanging Process[C]// 6th International Conference on Civil Engineering for Sustainable Development (Iccesd 2022), Khulna, Bangladesh. AIP Publishing, 2023: 110001.
[18] SEYYEDI S E, GORJI H, MIRNIA M J, et al.Prediction of Ductile Damage and Fracture in the Single- and Multi-Stage Incremental Hole-Flanging Processes Using a New Damage Accumulation Law[J]. The International Journal of Advanced Manufacturing Technology, 2022, 119(7): 4757-4780.
[19] BESONG L I, BUHL J, ÜNSAL I, et al.Development of Tool Paths for Multi-axis Single Stage Incremental Hole-flanging[J]. Procedia Manufacturing, 2020, 47: 1392-1398.
[20] AHMAD R A, HUSSAIN G, ULLAH N, et al.An Investigation on the Effects of Tool Rotational Speed and Material Temper on Post-ISF Tensile Properties of Al2219 Alloy[J]. Journal of Materials Research and Technology, 2021, 10: 853-867.
[21] 韩泽平, 曹丽杰. AA2195-AZ31B搅拌摩擦焊温度场数值模拟[J]. 热加工工艺, 2025, 54(15): 59-64.
HAN Z P, CAO L J.Numerical Simulation of Temperature Field during AA2195-AZ31B Friction Stir Welding[J]. Hot Working Technology, 2025, 54(15): 59-64.
[22] 姜旭, 朱冠昱, 王晓宏, 等. 5052铝合金板材渐进成形工艺参数双目标优化及试验验证[J]. 铝加工, 2024(5): 43-48.
JIANG X, ZHU G Y, WANG X H, et al. Double Objective Optimization and Experimental Verification of Incremental Forming Process Parameters of5052 Aluminium Alloy Sheet[J]. Aluminium Fabrication, 2024(5): 43-48.
[23] 王洺浩. 汽车轻量化材料镁合金的腐蚀防护技术应用现状与发展趋势[J]. 汽车实用技术, 2025, 50(9): 93-98.
WANG M H.Application Status and Development Trend of Corrosion Protection Technology for Automobile Lightweight Material Magnesium Alloy[J]. Automobile Applied Technology, 2025, 50(9): 93-98.
[24] 陈建丽, 曾德长. 1060铝板渐进成形参数的精英群体引导蜂群优化[J]. 机械设计与制造, 2025(8): 186-191.
CHEN J L, ZENG D C. Optimization of Progressive Forming Parameters of1060 Aluminum Sheet by Elite Group Guided Bee Colony[J]. Machinery Design & Manufacture, 2025(8): 186-191.
[25] 顾仲, 高锦张. 1060铝板单道次渐进成形圆孔翻边高度与壁厚分布的研究[J]. 锻压技术, 2019, 44(4): 48-56.
GU Z, GAO J Z.Study on Height and Wall Thickness Distribution of Hole-Flanging by Single-Pass Incremental Forming for 1060 Aluminum Plate[J]. Forging & Stamping Technology, 2019, 44(4): 48-56.
[26] 尚苗, 李言, 山顺坤, 等. 复杂形状零件单点渐进液压成形厚度分布研究[J]. 中国机械工程, 2025, 36(6): 1338-1344.
SHANG M, LI Y, SHAN S K, et al.Study on Thickness Distribution of Single Point Incremental Hydroforming of Complex Shaped Parts[J]. China Mechanical Engineering, 2025, 36(6): 1338-1344.