Drawing Of 5A06 Aluminum Alloy Cylindrical Cup With Double Side Pressure

Sheet metal forming is widely used in the manufacturing of automobile, airplane and meters. With the high speed development of aerospace industry, the component requirements of lightweight, high-intensity, high-precision, high efficiency, low consumption were proposed, aluminum-magnesium alloy and other light-weight materials are widely applied. However, the application of light-weight materials is confined for its low plasticity and poor formability. Comparing with the conventional deep drawing, the sheet metal hydroforming is one of the effective forming methods to increase the forming limitation of the aluminum-magnesium and other low plasticity, poor formability sheets, meanwhile this technology has the super flexibility and guaranty of quality, reducing the cost and trial period..On the basis of the traditional hydromechanical deep drawing, drawing with double side pressure (DDSP) technology is also loading hydraulic pressure on the upper surface of the blank. As the exist on positive pressure, the situation of the force deformation zone was improved, reducing the loading of transfer zone, increasing the allowable deformation, inhibiting the thinning effectively, improving the forming limit. PNPH technology provides a new way for the complex parts processing of sheet metal forming.In this paper, the component of aluminum alloy with tapered bottom is as a subject, the combination of method on simulation and experiment is adopted to investigate the relation between process parameters and part formability.The numerical simulation software ETA/Dynaform5.6 is employed which is based on LS-DYNA3D to investigate the forming process of DDSP aluminum alloy (5A06) part. The loading means of positive pressure was processed. The effects of different match relation of negative pressure and positive pressure on the thickness distribution were studied and the reasonable match relation of negative and positive pressure was obtained. And the stress analysis of the forming results was made and the developing regularity of plastic deformation of PNPH was analyzed. The change of stress trace of representative points in yield ellipse has been given out.The experimental research on the DDSP of aluminum alloy (5A06) part was made. The die structure of DDSP was designed and the best process parameters to improve the forming limit were given. The effect of process parameters on thickness distribution was summarized. The failure modes and failure mechanism were analyzed. And the qualified part was obtained. The variation rule of the maximum thickness strain in the forming process was given by measuring the strain on the forming process.