Finite element analysis of stiffness and static dent resistance of aluminum alloy double-curved panel in viscous pressure forming

The static dent resistance performance of the aluminum alloy double-curved panel formed using viscous pressure forming (VPF)was studied by finite element analysis,which mainly considers the forming process conditions.The whole simulation consisting of three stages,i.e.,forming,spring-back and static dent resistance,was carried out continuously using the finite element code ANSYS.The influence of blank holder pressure(BHP)and the drawbead on the stiffness and the static dent resistance of the panels formed using VPF was analyzed.The results show that the adequate setting of the drawbead can increase the plastic deformation of the double-curved panel,which is beneficial to the initial stiffness and the static dent resistance.There is an optimum BHP range for the stiffness and the static dent resistance.

Viscous Inner and Outer Pressure Forming Method of Thin-walled Tube and Its Application

Aiming at overcoming the difficulties in integral forming of thin-walled tubes with complex shapes, a novel forming method by inner and outer pressure through viscous was proposed. In this method, by dividing large deformation of the part into inner and outer pressure forming deformations, the limit deformation of tube part can be increased by several times. Meanwhile, the principle of viscous inner and outer pressure forming was provided, and key problems during the forming process such as reduction of the wall-thickness and instability wrinkling were analyzed. Thereby, the complex curved surface super-alloy GH3044 thin-walled tube with varying diameter ratio of 1.35（the ratio between the maximum and minimum diameters of the part） can be integrally formed by this method. The experimental surface of the formed part is superior in quality and the wall-thickness distribution is uniform. The results show that the viscous inner and outer pressure forming can provide a new approach for integral forming of thin-walled tubes with complex shapes.

Effect of aluminum particle on properties of viscous medium during warm viscous pressure bulging

Incorporating aluminum particles into viscous medium was proposed to improve the thermal conductivity of the viscous medium and the efficiency of warm viscous pressure forming(WVPF)process.The influence of aluminum particles on a viscous medium was investigated through settling,thermal conductivity,and compression experiments.Warm viscous pressure bulging(WVPB)experiments were conducted on polyetherimide(PEI)and AZ31B magnesium alloy sheets to determine the influence of the aluminum particles size and fraction on the forming efficiency and formed specimens based on the heating preparation times and profile curves,wall thicknesses and surface roughness values of the bulging specimens.The results show that the thermal conductivity of the viscous medium and the WVPF efficiency can be greatly improved via the addition aluminum particles with appropriate size and fraction under certain temperature condition,but have less influence on other properties of viscous medium.

SECTIONAL FINITE ELEMENT ANALYSIS OF COUPLED DEFORMATION BETWEEN ELASTOPLASTIC SHEET METAL AND VISCO-ELASTOPLASTIC BODY

The present paper is devoted to developing a new numerical simulation method for the analysis of viscous pressure forming （VPF）, which is a sheet flexible-die forming （FDF） process. The pressure-carrying medium used in VPF is one kind of semisolid, flowable and viscous material and its deformation behavior can be described by the visco-elastoplastic constitutive model. A sectional finite element model for the coupled deformation analysis between the viscoelastoplastic pressure-carrying medium and the elastoplastic sheet metal is proposed. The resolution of the Updated Lagrangian （UL） formulation is based on a static explicit approach. The frictional contact between sheet metal and visco-elastoplastic pressure-carrying medium is treated by the penalty function method. Coupled deformation between sheet metal and visco-elastoplastic pressure-carrying medium with large slip is analyzed to validate the developed algorithm. Finally, the viscous pressure bulging （VPB） process of DC06 sheet metal is simulated. Good agreement between numerical simulation results and experimental measurements shows the validity of the developed algorithm.