Investigation On The Aluminum-magnesium Alloy Sheet Forming By Hydrodynamic Deep Drawing Process Based On Numerical Simulation

With the light-weight requirement of automobile, aviation and aerospace industries, aluminum-magnesium alloy, titanium alloy and other light-weight materials are widely applied. However, compared with the deep punching steel, the application of light-weight materials is confined for its poor formability and low plasticity. The hydrodynamic deep drawing (HDD) process is one of the effective methods to increase the forming limitation and reduce the forming steps of the aluminum-magnesium alloy and other low plasticity, poor formability sheets, because of the super flexibility, better qualification and low cost.To meet the forming need of aluminum-magnesium alloy and other low plasticity materials, the parameters of sheet, mould and processing of the aluminum-magnesium alloy (5A06) flat bottom cylindrical cup's HDD process were carried out by the numerical simulation that was based on the large non-linear dynamic explicit analytical software ETA/DYNAFORM5.5. The chamber pressure variations to the formability effects were discussed. In the HDD process of the hemispherical bottom cylindrical cup, the effects of initial inverse bulging pressure and chamber pressure on the wall-thickness distribution, wrinkle and crack were analyzed. The roles of soft bead were also discussed, which can decrease the suspended area between punch and die and overcome the deficiences of hemispherical bottom cylindrical cup. The reasonable match relation between the initial inverse bulging pressure and chamber pressure was obtained. And the reliability of the numerical simulation was proved by the experiment.In this paper, to solve the problems of crack and deforming deficiency in the stamping process of the automobile panels, the numerical simulation of the large curved surface exhaust panel's HDD process was carried out. The chamber pressure variations to the automobile panel's formability effects were analyzed by taking the final wall-thickness distribution as standard. And the effects of different loading paths on the forming quality were investigated. The optimal loading curve of chamber pressure was obtained and the attaching capability and rigidity were increased.