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Study on hydroforming of AA6061-T6 aluminum alloy sheet based on upper sheet

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Abstract

Forming large thin-walled hemispherical parts by hydroforming, serious thinning of wall thickness, instability of suspension area, and fracture are often accompanied. In order to solve the above problems, this paper takes AA6061-T6 aluminum alloy thin-walled hemispherical parts as the research object, and uses the method of finite element numerical simulation analysis and experimental verification to carry out the formability analysis of double-layer sheet hydroforming. In order to improve the accuracy of numerical simulation, uniaxial tensile tests are carried out on AA6061-T6 tensile specimens. Based on the BP neural network prediction model, a constitutive model that can truly reflect the plastic deformation characteristics of materials is established, which can provide more accurate material properties for numerical simulation. In this paper, the wall thickness and fittability of the parts are taken as the evaluation indexes, and the simulation analysis of the double-layer sheet hydroforming is carried out combined with the pre-bulging process, and the process flow of the single-sheet and the double-layer sheet hydroforming is compared and analyzed. The forming law of formed sheet under different friction coefficient between sheets and different upper sheet thickness is discussed. In addition, the influence of different temperature on the forming quality of parts is also discussed. It is found that the sheet metal will soften at the appropriate temperature, and the wall thickness distribution of the parts suspending area will be further improved.

Finally, the forming experiments are carried out using the optimized process conditions, and the results are basically consistent with the simulation results. The results show that the research can effectively provide scientific guidance for the forming of large thin-walled hemispherical parts.

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Data availability

The data obtained in the framework of this study are available to the journal upon request.

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Funding

This paper was financially supported by Harbin academic leader fund (2017RAXXJ008) and National Natural Science Foundation of China (51975167).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Harbin University of Science and Technology, Harbin, 150040, China

    Xiao Jing Liu, Zhi He Zhang, Xue Feng Ma, Chao Li & Ying Ying Zhou

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  1. Xiao Jing Liu
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  2. Zhi He Zhang
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Contributions

Zhi He Zhang: conceptualization, methodology, writing—original draft preparation, experimental scheme design. Xiao Jing Liu: writing—reviewing and editing. Xue Feng Ma: experiment. Chao Li: verification. validation. Ying Ying Zhou: supervision.

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Correspondence to Xiao Jing Liu.

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Liu, X.J., Zhang, Z.H., Ma, X.F. et al. Study on hydroforming of AA6061-T6 aluminum alloy sheet based on upper sheet. Int J Adv Manuf Technol 123, 4447–4464 (2022). https://doi.org/10.1007/s00170-022-10534-3

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  • DOI: https://doi.org/10.1007/s00170-022-10534-3

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