Transactions of Nonferrous Metals Society of China The Chinese Journal of Nonferrous Metals

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中国有色金属学报(英文版)

Transactions of Nonferrous Metals Society of China

Vol. 22    No. 2    December 2012

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Pre-bulging effect during sheet hydroforming process of aluminum alloy box with unequal height and flat bottom
LANG Li-hui1, WANG Yong-ming1, XIE Ya-su1, YANG Xi-ying1, XU Ying-qiang2

1. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China;
2. Sheet Metal Factory, Shanghai Aircraft Manufacturing Corporation, Shanghai 200436, China

Abstract:Pre-bulging effect on the sheet hydroforming process of irregular box with unequal height and flat bottom was investigated by means of numerical simulation and experiment. The influences of pre-bulging height and pre-bulging pressure on the forming were discussed respectively. The pressure loading path was optimized. The results show that pre-bulging has important influences on the forming results. Too high pre-bulging height causes the crack and obvious crease at the punch nose near the lowest corner. Too low pre-bulging height causes fracture at the punch nose of the highest corner. Pre-bulging pressure has a smaller effect on the fracture at the punch nose of the highest corner when the pre-bulging height is reasonable. But over high pre-bulging pressure causes crack and obvious crease at the punch nose near the lowest corner. Failure can be avoided by using reasonable pre-bulging height and pre-bulging pressure.

 

Key words: aluminum alloy; sheet hydroforming; pre-bulging; irregular box

ISSN 1004-0609
CN 43-1238/TG
CODEN: ZYJXFK

ISSN 1003-6326
CN 43-1239/TG
CODEN: TNMCEW

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