Abstract
The formability of 1 mm thick AA5182 aluminum alloy sheets in deep drawing of square cups by hydroforming was studied. The influence of process parameters (peak pressure, pressure path, and blank holding force) on formability was investigated through numerical simulations and validated with experimental work. The experiments were designed using the Taguchi method. The minimum thickness in the formed cups (at the bottom corners) and the minimum corner radius that can be achieved were considered as the criteria for evaluation of formability. The peak pressure was the most important process parameter affecting thinning and the minimum corner radius that can be achieved. The variation of the pressure path had the least effect on formability. Regression models were developed for prediction of minimum thickness in the cup and the corner radius as a function of peak pressure and blank holding force.
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