Numerical study of microplastic impact hydroforming process

Abstract

Microplastic forming is a promising micro production technology with great advantages due to its excellent mechanical property, definite thermal stability and low manufacture cost. Impact hydroforming technology is a high strain rate forming method that can improve the limit of metal microplastic forming. In this study, FE-simulation is carried out to reveal the influence of different process parameters on the forming behaviors of micro impact hydroforming process. The forming depth is improved with the increase of the velocity. In addition, different areas of the formed parts are affected by the liquid pressure, bottom fillet, blank holder and friction condition. The strain distribution is inhomogeneous, and the ball head portion has the largest strain. The simulation result also shows the thinning effect is greatest at the center point and decreases from the center to the radius. Through the analysis of the process feasibility, the simulation results of microplastic impact hydroforming can provide references to the design and manufacture of actual impact hydroforming parts.