Abstract
The explosively forming projectile (EFP) had been traditional adopted for the aluminum thin-walled corrugated sheet, whose deformation range is large but the formability is poor, and this process usually has problems of poor surface quality, long manufacturing cycle and high cost. The active hydroforming process was suggested to solve these issues during EFP. A new technology named as blank bulging by turning the upside down active hydroforming technology was proposed to overcome difficulties in non-uniform thickness distribution and cracking failure of corrugated sheet during the conventional hydroforming process. Both numerical simulations and experiments were conducted for this new technology. The result show that the deformation capacity of aluminum alloys can be improved effectively, and the more uniform distribution of wall thickness was obtained by this new method. It is conducted that the new method is universal for thin-walled, shallow drawing parts with complex section.
Highlights
Aluminum alloy corrugated sheet, which has the advantages of light weight, excellent bearing capacity and high performance in energy absorption, is widely used in aerospace structures [1]
The explosively forming projectile (EFP) had been traditional adopted for the aluminum thin-walled corrugated sheet, whose deformation range is large but the formability is poor, and this process usually has problems of poor surface quality, long manufacturing cycle and high cost
The active hydroforming process was suggested to solve these issues during EFP
Summary
Aluminum alloy corrugated sheet, which has the advantages of light weight, excellent bearing capacity and high performance in energy absorption, is widely used in aerospace structures [1]. On the other hand, hydroforming is an advanced forming technology in which the flexible liquid medium is used to replace the traditional rigid die It has the advantages of saving process time, tooling costs and can produce good quality of forming parts. Meng Bao [5] formed a box part with super wide flange using hydrodynamic deep drawing and the process window of cavity pressure was established through stress analysis of the corner and straight regions. These analytical models provided rapid and reasonably accurate results for the design of warm hydroforming process. The stress state of aluminum alloy thin-walled corrugated sheet in active hydroforming process has been analyzed, and the blank bulging by turning the upside down hydroforming method was presented to overcome the cracking failure
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