Sheet hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as higher forming limitation, good quality of the formed parts and complicated parts can be formed. The main advantage is that the uniform pressure can be transferred to everywhere at the same time. Based on the hydromechanical deep drawing (HDD) with uniform pressure onto the blank, the multi-sheet hydroforming with the very thin middle layer of an aluminium membrane (0.011 mm) is investigated. The cladding materials used for the internal and the external layers were a pure soft aluminium (APP211) and a soft steel (DC04), respectively, for analysing the forming process. The results reveal that the formability of the thin middle layer has been improved significantly, and the wrinkling and the fracture are totally avoided although the middle layer is extremely thin. The formability of the thin middle layer is controlled by the internal or the external layers. The friction coefficients between the layers affect the forming process very much. The larger the coefficients are, the better the middle layer can be formed. The variation of the pressure in the die cavity affects the forming of the middle thin layer significantly, and too high pre-bulging pressure will damage the middle layer. The optimal pre-bulging pressure is necessary to be used in forming process to avoid the wrinkling and the fracture.
Multi-layer sheet hydroforming: Experimental and numerical investigation into the very thin layer in the middle
Journal of Materials Processing Technology ; 170 , 3 ; 524-535
2005
12 Seiten, 18 Bilder, 3 Tabellen, 22 Quellen
Article (Journal)
English
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