EFFECTS OF SPECIFIED BLANK SIZE ON BODY WRINKLING DURING HYDRODYNAMIC DEEP DRAWING OF TAPERED RECTANGULAR BOX

In this paper, the forming features of tapered rectangular box during hydrodynamic deep drawing are studied by means of FEM.The effect rules of square blank corner corner amount on body wrinkling are recognized and corresponding methods are discussed. At last, the results of FEM are verified by experi- ment.

Effects of Loading Paths on Hydrodynamic Deep Drawing with Independent Radial Hydraulic Pressure of Aluminum Alloy Based on Numerical Simulation

In order to meet the forming demands for low plasticity materials and large height-diameter ratio parts, a new process of hydrodynamic deep drawing （HDD） with independent radial hydraulic pressure is proposed. To investigate the effects of loading paths on the HDD with independent radial hydraulic pressure, the forming process of 5A06 aluminum alloy cylindrical cup with a hemispherical bottom was studied by numerical simulation. By employing the dynamic explicit analytical software ETA/Dynaform based on LS-DYNA3D, the effects of loading paths on the sheet-thickness distribution and surface quality were analyzed. The corresponding relations of the radial hydraulic pressure loading paths and the part＇s strain status on the forming limit diagram （FLD） were also discussed. The results indicated that a sound match between liquid chamber pressure and independent radial hydraulic pressure could restrain the serious thinning at the hemisphere bottom and that through adjusting radial hydraulic pressure could reduce the radial tensile strain and change the strain paths. Therefore, the drawing limit of the aluminum cylindrical cup with a hemispherical bottom could be increased significantly.

Process window diagram of conical cups in hydrodynamic deep drawing assisted by radial pressure

Major defects in forming of conical cups are wrinkles and rupture.Hydrodynamic deep drawing assisted by radial pressure（HDDRP） is a sheet hydroforming process for production of shell cups in one step.In this work,process window diagrams（PWDs） for Al1050-O,pure copper and DIN 1623 St14 steel are obtained for HDDRP process.The PWD is determined to provide a quick assessment of part producibility for sheet hydroforming process.Finite element method is used for this purpose considering the process parameters including pressure path,and the blank material and its thickness.Numerical results are validated by experiments.It is shown that the sheets with less initial thickness and higher strength show better formability and uniformity of thickness distribution on final product.The results demonstrate that the obtained PWD can predict appropriate forming area and probability of rupture or wrinkling occurrence under different pressure loading paths.

Hydrodynamic deep drawing of double layered conical cups

Hydrodynamic deep drawing assisted by radial pressure is an advanced sheet forming technology with great advantages such as higher drawing ratio, good surface quality and higher dimensional accuracy. In this process, both the bottom surface and the peripheral edge of sheets are under hydrodynamic pressure, so that the forming procedure is more uniform with low failure probability. Multi-layered sheets with complex geometries could be formed more easily with this technique compared with other traditional methods. Rupture is the main irrecoverable failure form in sheet forming processes. Prediction of rupture occurrence is of great importance for determining and optimizing the proper process parameters. In this research, a theoretical model was proposed to calculate the critical rupture pressure in production of double layered conical parts with hydrodynamic deep drawing process assisted by radial pressure. The effects of other process parameters on critical rupture pressure, such as punch tip radius, drawing ratio, coefficient of friction, sheet thickness and material properties were also discussed. The proposed model was compared with finite element simulation and validated by experiments on Al1050/St13 double layered sheets, where a good agreement was found with analytical results.

Formation of Aluminum-magnesium Alloy Cup by Hydrodynamic Deep Drawing with Twin-loading Paths

In order to overcome the limitation of hydro-rim deep drawing, a new process of hydrodynamic deep drawing （HDD） with independent radial hydraulic pressure was proposed. By employing the dynamic explicit analytical software ETA/DynaformS.5 which is based on LS-DYNA3D, the effects of independent radia! hydraulic pressure on the stress, strain and the sheet-thickness of aluminum-magnesium cylindrical cup with a hemispherical bottom were analyzed by numerical simulation. The feature of stress distribution is that there exists a stress-dividing circle in the flange, and the radius of dividing circle was determined by theoretical analysis and stimulation. The experimental results indicate that the reasonable match of independent radial hydraulic pressure and liquid chamber pressure can effectively reduce the thinning at the bottom of hemisphere, decrease the radial stress-strain, and improve the drawing limit of aiuminum-magnesium alloy cylindrical cup.

Forming Process of Strong Anisotropic Material Based on the Hydrodynamic Deep Drawing with Radial Pressure

The hydrodynamic deep drawing process enables net shape or near net shape forming of complicated sheet metal parts made from difficultly forming materials, such as aluminium or high strength steels. Based on the conventional hydrodynamic deep drawing process, a new process, hydrodynamic deep drawing process, in which radial pressure is applied to the rim of the blank, is proposed. This new process has been analysed using FEM simulations and the obtained results have been compared with the experimental results. The material used in the experiments was Al-Mg-Si alloy, and in the FEM-simulations the elastic-plastic behaviour of Al-Mg-Si alloy was modelled using Barlat＇s 89 yield criteria.

Inner wrinkling control in hydrodynamic deep drawing of an irregular surface part using drawbeads

Inner wrinkling phenomenon is more likely to develop during hydrodynamic deep drawing （HDD） of complicated component-forms due to the higher demand for controlling deformation sequences. Aiming at the problems in control of inner wrinkling for an irregular surface part featured with both concavity and convex, this research proposes an optimal design method of drawbead parameters to change the material flow. According to theoretical analysis of the mechanism of inner wrinkling, optimizing cavity pressure only is unreasonable to form a wrinkle-free deep-drawn part, so semi-circular drawbeads are employed. The effects of layout and height of drawbeads on forming results are discussed, and a process window is established based on evaluation indicators including the anti-wrinkle coefficient and the minimum wall thickness. Experiments are carried out to validate the process window, and the wall thickness and the wrinkle height are measured and compared with numerical findings. The results show that the anti-wrinkle ability of drawbeads weakens with increasing oblique angle and distance from the die center, while the wall thickness increases with increasing oblique angle and distance, and the inner wrinkling can be completely suppressed by drawbeads arranged in zones I and II with optimum penetration.