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Investigation into the overlapping sheet hydraulic bulge and its formability

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Abstract

This paper presents the overlapping sheet hydraulic bulge, which can effectively improve the formability of low plasticity sheet metal by controlling or changing the force conditions and stress states of the target sheet. In the process, the material performance and thickness of the overlapping sheet play an important role in the formability of the target sheet. In this paper, the overlapping sheet hydraulic bulge process is theoretically analyzed. Also, limit bulging tests of no-overlapping sheet, different overlapping sheet materials and different overlapping sheet thicknesses are carried out by taking the aluminum alloy 2B06 as the research object, and the limit bulging heights of specimens are analyzed. Meanwhile, various aspects such as the specimen geometric shape and thickness distribution have been studied to verify the accuracy of the theoretical analysis. Finally, FEM is used to analyze the forming process to explain some results which were found in the test, and the comparison shows good agreement between the numerical results and test data. The results show that the overlapping sheet-forming method is beneficial for the formability attributes of target sheets. Deformation uniformity and the ability of plastic deformation can be improved by choosing higher strength coefficient K, larger work hardening exponent n and proper thickness of the overlapping sheet.

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Abbreviations

P :

Hydraulic pressure (MPa)

P 1 :

Reversed pressure in central area of target sheet (MPa)

P 2 :

Reversed pressure in flange area of target sheet (MPa)

K :

Strength coefficient of overlapping sheet (MPa)

n :

Work hardening exponent of overlapping sheet

t :

Overlapping sheet thickness (mm)

K 1 :

Overlapping sheet strength coefficient (MPa)

n 1 :

Overlapping sheet hardening exponent

K 2 :

Target sheet strength coefficient (MPa)

n 2 :

Target sheet hardening exponent

σ 1 :

Stress of overlapping sheet (MPa)

σ 2 :

Stress of target sheet (MPa)

σ ρ :

Radial stress of overlapping sheet (MPa)

σ θ :

Circumferential stress of overlapping sheet (MPa)

σ ′ ρ :

Radial stress of target sheet (MPa)

σ ′ θ :

Circumferential stress of target sheet (MPa)

σ t :

Thickness stress of target sheet (MPa)

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Acknowledgments

The authors gratefully acknowledge the financial support from National Science and Technology Major Project with Grant No. 2014ZX04002041 and National Science Foundation of China with Grant No. 51175024. Meanwhile, Associate Professor Tiejun Gao of Shenyang Aerospace University, definitely gains our deepest gratitude for his contribution to this course.

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beihang University, No. 37 Xueyuan Road, Beijing, 100191, China

    Yao Wang, Lihui Lang, Rizwan Zafar, Zhiying Sun & Quanda Zhang

Authors
  1. Yao Wang
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  2. Lihui Lang
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  3. Rizwan Zafar
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  4. Zhiying Sun
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  5. Quanda Zhang
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Corresponding author

Correspondence to Yao Wang.

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Technical Editor: Alexandre Mendes Abrao.

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Wang, Y., Lang, L., Zafar, R. et al. Investigation into the overlapping sheet hydraulic bulge and its formability. J Braz. Soc. Mech. Sci. Eng. 38, 1635–1645 (2016). https://doi.org/10.1007/s40430-015-0430-5

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  • DOI: https://doi.org/10.1007/s40430-015-0430-5

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