17.05.2018 Die Science: Splitting in a stretch flange?

- The Fabricator

(https://ads.thefabricator.com/delivery/ck.php?
oaparams=2__bannerid=210__zoneid=1__cb=4b39499820__oadest=http%3A%2F%2Fwww.primapower.com)

Home (/) / Article (/?filter=article) / Stamping (/?filter=article&category=stamping) / Die Science: Splitting in a stretch flange?

ange+is+a+part+feature+in+which+the+metal+is+bent+along+a+concave+or+convex+axis.+This+curvature&img=https://static.thefabricator.com/a/die-

Die Science: Splitting in a stretch flange?

Forming factors to consider
STAMPING JOURNAL NOVEMBER/DECEMBER 2009 (/PUBLICATION/SJ/NOVEMBER-DECEMBER-2009)
JULY 18, 2017
BY: ART HEDRICK (/AUTHOR/ART-HEDRICK)

Splitting in the proximity of a stretch flange is one of the most common forming
failures that occur in sheet metal stamping.

What is Stretch Flange?

Also known as a tension flange , a stretch flange is a part feature in which the
metal is bent along a concave or convex axis. This curvature forces the material to
stretch from a short length of line to a longer length of line. Because the metal is
being stretched, it has a tendency to crack or split along the curved surface (see
Figure 1 ) .

Stretch flanges are common design features in stamped parts. They typically are
added to increase a part’s stiffness and rigidity.

Part features such as the length of flange, the radial profile, and the metal type (https://static.thefabricator.com/a/die-science-splitting-in-a-
and thickness determine the difficulty of the flange. Long flanges formed in an stretch-flange--1498504586.jpg?size=1000x1000)
area with a small radial profile are the most difficult, especially if they are made of
high-strength metals (see Figure 2 ). The smaller the profile radius, the more difficult it will be to keep the flange from splitting.

Stretch Distribution
Of all the factors controlling the success of the stretch flanging operation, the type of material being flanged, its thickness, and its mechanical
properties are the most influential. Materials exhibiting good stretchability and stretch distribution characteristics are best-suited for stretch flanging
operations.

ADVERTISEMENT

(https://ads.thefabricator.com/delivery/ck.php?
oaparams=2__bannerid=123__zoneid=217__cb=df2171064f__oadest=http%3A%2F%2Fwww.cpec.com)

In the case of ferrous metals, such as plain carbon steels, the metal’s stretching characteristics are best expressed by evaluating the material’s n
value. Also known as the material’s work-or strain hardening exponent, this numeric value represents the metal’s ability to distribute stretch though
the process of strain hardening.

The higher the number, the more evenly and uniformly the material will stretch. For carbon steel, the n value is from 0.1 to 0.3. Low-carbon steel
typically has an n value of about 0.22 or higher, whereas high strength carbon steel might have values near 0.11 or lower.

This ability to stretch is known as stretch or strain distribution . The metal’s stretch distribution characteristics do not stretch over a large surface
area but rather stretch in a very confined, isolated area. This is commonly called localized straining .

Performing
To make a long stretch flange out of a material with a lower n value, a perform operation might be needed before the flanging operation.

The basic purpose of performing the blank is to gain the same surface area that is contained in the stretch flange geometry by stretching the metal
first. This gives the process engineer a chance to force stretch distribution by altering the punch shape of the preforming operation. In other words,
preforming the material stretches more surface area of the metal needed in the flange.

Many tooling engineers elect to use a “roller coaster” perform shape to prevent severe localized stretching. As long as the surface area increase is
equal to or greater than the surface area of the flange, the likelihood of splitting is reduced.

Blank and Hole Edge Quality

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 1/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator
Cutting metal before the flanging process can affect the results. The normal metal cutting process, with the exception of speciality operations such
as GRIP flow ® or fine blanking, involves exceeding the metal’s shear involves exceeding the metal’s shear strength, which results in the metal
fracturing or breaking free. However, before the metal can fracture, the punch must cut or extrude the metal.

(https://static.thefabricator.com/a/die-science-splitting-in-a-stretch-flange--1498760713.jpg?size=1000x1000)
Figure 1
In a stretch flange, metal has a tendency to crack or split along the curved surface.

The basic process results in a cut metal edge that combines a portion of shear and a portion of fracture. This shear/ fracture relationship, often
referred to as the metal’s cut band , can be seen on the edge of any conventionally cut part (see Figures 3 ).

Oftentimes grinding or sanding the edge of the blank before forming results in a more successful stretch flanging operation. There are two basic
reasons for this result:

1. The smooth portions of the cut has more edge-stretching capability than the fracture portion of the cut. Smoothing out this fracture zone of
the metal results in more edge-stretching ability for the material
2. During the metal cutting process, the metal often is deformed in compression around the punch or cutting section. This metal deformation
usually results in work hardening at the cut edge. This cold worked material has less stretching ability than unworked material. Grinding the
edge of the blank often removes the cold-worked material and smooths the cut edge.

Shaving the Blank Edge

Cut edges in areas that will be exposed to tension must be kept sharp and free of chips or severely damaged edges. Even a small chip in the
cutting edge can create a weak spot or stress riser in the cut edge. When this edge is exposed to tension, it typically begins to split at the stress
riser location.

Many stampers shave the cut edge to keep it smooth and remove the work-hardened edge. Shaving is more of a machining or broaching process
than a metal cutting process. Unlike a conventional piercing or trimming punch, a shaving punch is ground to a sharp point resembling a lathe or
sharper tool bit. It removes a small portion of the cut edge using a positive rake angle. This leaves the cut edge smooth and also helps to remove
some of the cold-worked material on the edge.

One drawback of shaving in a die is that it often leaves small shaving slivers in the tool, which can cause problems. Most companies use
commercial vacuum units to keep the die free from slivers.

Data-based Forming
The notorious stretch flange always has been—and probably always will be—somewhat of a forming problem. Success begins with a realistic
product design followed by a good, data-based forming process. Understanding all of the factors that affect the metal’s edge-stretching ability is the
key.

Until next time… Best of luck!

 Slide Show | 4 Images

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 2/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator

(https://static.thefabricator.com/a/die-science-splitting-in-a-stretch-flange--1498760718.jpg?size=1000x1000)
(https://static.thefabricator.com/a/die-science-splitting-in-a-stretch-flange--1498760723.jpg?size=1000x1000)

You May Also Like

(/article/stamping/sheet-metal-stamping-101-part-v) (/article/stamping/stamping-101-die-basics)
Sheet Metal Stamping 101, Part V Die Science: Stamping 101 - Die basics

(/article/stamping/sheet-metal-stamping-101-part-v) (/article/stamping/stamping-101-die-basics)

(/article/stamping/blanking-questions-have-you-on-the-edger) (/article/stamping/solving-stretch-flange-problems-part-i-)
Blanking questions have you on the edge? Die Science: Solving stretch flange problems (Part I)

(/article/stamping/blanking-questions-have-you-on-the-edger) (/article/stamping/solving-stretch-flange-problems-part-i-)

Art Hedrick
Contributing Writer
Dieology LLC
8730 10 Mile Rd. SE.
Rockford, MI 49341
Phone: 616-894-6855

http://www.dieology.com (http://www.dieology.com)
Contact via email (mailto:dieology@pathwaynet.com)

More Content by Art Hedrick (/author/art-hedrick)

Author of the "Die Science" column in STAMPING Journal®, Art also has written technical articles on stamping die design and build for a number of
trade publications. A recipient of many training awards, he is active in metal stamping training and consulting worldwide.

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 3/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator
Published In...

STAMPING Journal
STAMPING Journal is the only industrial publication dedicated solely to serving the needs of the metal
stamping market.

Preview the Digital Edition (http://www.stampingjournal-digital.com)

Subscribe to STAMPING Journal (/subscription/pub/sj)

Read more from this issue (/publication/sj/november-december-2009)

(https://www.twitter.com/stampingjournal)


Related Companies
Dieology LLC (https://www.thefabricator.com/directory/showroom/dieology-llc)

0 Comments The Fabricator 

1 Login

Sort by Best
 Recommend ⤤ Share

Start the discussion…

LOG IN WITH
OR SIGN UP WITH DISQUS ?

Name

Be the first to comment.

ALSO ON THE FABRICATOR

FlexDrill TRD vertical machining center suitable for tube, Should your operation convert from spot welding to laser
pipe processing keyhole welding?
1 comment • 2 months ago 1 comment • 3 months ago
FlexArm Stephen — I may have a bias opinion but this thing is BrandonABoyer — What about safety concerns? Laser welding
awesome! operations need to take place in an enclosed space to prevent
ocular damage.Also I …

Worst. Advice. Ever. - The Fabricator Still Building America—Spreading the message about the
1 comment • a month ago welding trade
Laura Roberts — By AWS D1.1 standards prequalified WPS's for 1 comment • 5 months ago
vertical welding positions are required to be vertical upwards. Tiffany Noel Orff — Love this!
Perhaps that's …

✉ Subscribe d Add Disqus to your siteAdd DisqusAdd 🔒 Privacy

SITE SPONSOR

(https://ads.thefabricator.com/delivery/ck.php?

oaparams=2__bannerid=525__zoneid=473__cb=5bce4144ec__oadest=http%3A%2F%2Fwww.cpec.com)

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 4/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator

(https://ads.thefabricator.com/delivery/ck.php?

oaparams=2__bannerid=55__zoneid=218__cb=2db22a14cb__oadest=http%3A%2F%2Fwww.greenerd.com%2F)

Upcoming Industry Events

ALAW® – Advanced Laser Applications
Workshop (/event/alaw-advanced-laser-
applications-workshop-1)
JUNE 4-6, 2018 | PLYMOUTH, MI
FABTECH Canada (/event/fabtech-canada)
JUNE 12-14, 2018 | TORONTO, ON
Atlantic Design & Manufacturing
(/event/atlantic-design-manufacturing)
JUNE 12-14, 2018 | NEW YORK, NY
International ThermProcess Summit (ITPS)
and the International Finishing & Coatings
Summit (IFCS) (/event/international-
thermprocess-summit-itps-and-the-
international-finishing-coatings-summit-ifcs-)
JULY 30 - AUGUST 1, 2018 | ATLANTA, GA
International Robot Safety Conference
(/event/international-robot-safety-conference)
OCTOBER 9-11, 2018 | DETROIT, MI
Northeast Lean Conference 2018
(/event/northeast-lean-conference-2018)
OCTOBER 10-11, 2018 | PROVIDENCE, RI
EuroBLECH 2018 (/event/euroblech-2018)
OCTOBER 23-26, 2018 | HANOVER, DEU
FABTECH (/event/fabtech-1)
NOVEMBER 6-8, 2018 | ATLANTA, GA
Powder Coating 2019 Technical Conference
(/event/powder-coating-2019-technical-
conference)
APRIL 1 - 4, 2019 | ORLANDO, FL

See All Industry Events » (/?filter=event)

(https://ads.thefabricator.com/delivery/ck.php?

oaparams=2__bannerid=1099__zoneid=220__cb=905a572e77__oadest=http%3A%2F%2Fwww.diedesignsoftware.com%2Fproducts%2Flogopress3-
3d-die-design)

Most Popular Content This Week

A wireless foot pedal and a spud wrench
(/blog/a-wireless-foot-pedal-and-a-spud-
wrench)
Meridian Magnesium fire spotlights supply
disruption vulnerability (/blog/meridian-
magnesium-fire-spotlights-supply-disruption-
vulnerability)
Tips for successful robotic aluminum welding
(/article/automationrobotics/tips-for-
successful-robotic-aluminum-welding)
Huntington Ingalls Industries partners with 3D
Systems to accelerate adoption of 3-D
printing (/news/additive/huntington-ingalls-
industries-partners-with-3d-systems-to-
accelerate-adoption-of-3-d-printing)
Tips for preparing your material before
welding (/article/cuttingweldprep/tips-for-

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 5/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator
preparing-your-material-before-welding)
NBT announces 2018 manufacturing camp
grant recipients
(/news/shopmanagement/nbt-announces-
2018-manufacturing-camp-grant-recipients)
Nucor to build galvanizing line at Arkansas
sheet mill (/news/metalsmaterials/nucor-to-
build-galvanizing-line-at-arkansas-sheet-mill)
Big River Steel CEO attends White House
summit on artificial intelligence
(/news/metalsmaterials/big-river-steel-ceo-
attends-white-house-summit-on-artificial-
intelligence)
Piab’s Flexible Suction Cup Mount comprises
interchangeable parts for customization
(/product/materialshandling/piab-s-flexible-
suction-cup-mount-comprises-
interchangeable-parts-for-customization)
Fronius’ TransSteel 2200 inverter power
source welds aluminum, copper silicon alloys
(/product/arcwelding/fronius-transsteel-2200-
inverter-power-source-welds-aluminum-
copper-silicon-alloys)

Visit our Affiliated Websites

(https://www.fmanet.org)

(https://www.canadianmetalworking.com) Membership (https://www.fmanet.org/membership)

Features (https://www.canadianmetalworking.com/features/) Training (https://www.fmanet.org/training)
Blogs (https://www.canadianmetalworking.com/blogs/) News (https://www.fmanet.org/blog)
News (https://www.canadianmetalworking.com/news/) Events (https://www.fmanet.org/events)
New Products (https://www.canadianmetalworking.com/products/)

(https://www.fabtechexpo.com)

FABTECH News (https://www.fabtechexpo.com/blog)

Attend (https://www.fabtechexpo.com/attend)
Exhibit (https://www.fabtechexpo.com/exhibit)
Education Program (https://www.fabtechexpo.com/learn)

(https://www.nutsandboltsfoundation.org)

Scholarships (https://www.nutsandboltsfoundation.org/scholarships)
Manufacturing Camps
(https://www.nutsandboltsfoundation.org/camps)
News (https://www.nutsandboltsfoundation.org/news)
Donate (https://www.nutsandboltsfoundation.org/donate)

Subscriptions (/subscription)

Advertise with Us (/mediakit)

Contact Us (/contact-us)

En Español (/espanol)

Industry Tradeshows (/?filter=event)

FMA Store (https://www.fmanet.org/store)

Job Board (https://jobs.fmanet.org)

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 6/7
17.05.2018 Die Science: Splitting in a stretch flange? - The Fabricator
TheFabricator.com provides metal fabrication professionals with market news, the industry's best articles, product news, and conference information from the
Fabricators & Manufacturers Association, Intl. (https://www.fmanet.org)

(/publication/fab) (/publication/sj) (/publication/pwt) (/publication/tpj)

(/pwtv) (/tpjtv)

© 2018 FMA Communications, Inc. All rights reserved.

2135 Point Blvd., Elgin, IL 60123 | 815-399-8700 | info@thefabricator.com

(mailto:info@thefabricator.com)

Terms of Use (https://www.fmanet.org/terms-of-use) | Privacy Policy (https://www.fmanet.org/privacy-

policy)

https://www.thefabricator.com/article/stamping/die-science-splitting-in-a-stretch-flange- 7/7