Forming characteristics of hole flanging on three kind of thick metal plates, flat, cylindrical and spherical, are investigated by experiment and FEM simulation. Test material is pure aluminum A1050. The punch size is constant, three cases of inner diameters of dies, five cases of blank thickness and five cases of the diameters of the pre-holes are adopted in experiments and simulations. Shapes of boss parts by hole flanging on thick metal plate are three types, that is, the shape with ironing outside of the boss, without ironing and with fracturing. As the results of this study, these three types can be classified by relation between sizes of the tools and the blank. And it is clear that forming hight of hole flanging can be obtained by the relation between the clearnace and diameter of the pre-hole.
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