Analysis of Thickness Variation in 2219 Aluminum Alloy Ellipsoid Shell with Differential Thickness by Hydroforming
Abstract
:1. Introduction
2. Experimental Section
2.1. Sheet Material and Ellipsoid Shell Size
2.2. Hydroforming Process of Plates with Differential Thickness
2.3. Setup and Procedure
3. Thickness and Strain Distributions
3.1. Thickness Distributions
3.2. Strain Distributions
4. Mechanical Analysis of the Influence of Friction on Hydroforming
- The unsupported zone is not deformed under the action of hydraulic pressure, and the shape of the unsupported zone is approximately a cone;
- The material of the plate is an elastic–perfectly plastic material;
- The deformation is a simple loading process.
5. Conclusions
- (1)
- Compared with conventional deep drawing, hydroforming can improve the thickness distribution within the thin zone of the differential thickness plates. With the increase in hydraulic pressure, the overall thickness thinning rate within the thin zone of the drawn ellipsoid shell decreases. When the hydraulic pressures are 0, 3.7 MPa, and 5.2 MPa, the maximum thickness thinning rates are 13.3%, 9.6%, and 8.8%, respectively.
- (2)
- With the increase in hydraulic pressure, the radial strain and circumferential strain in the thin zone will both decrease, along with the absolute value of the normal strain. Consequently, the overall degree of plastic deformation in the thin zone will also be reduced.
- (3)
- During hydroforming, the occurrence of interfacial shear stress between the aluminum plate and the elastic auxiliary plate and the punch is beneficial for the formability of differential thickness plates. This interfacial friction can reduce the radial stress within the thin zone, alter the deformation state of the aluminum plate, and restrain excessive thinning. With increases in hydraulic pressure and friction coefficient, the influence of friction on hydroforming becomes more significant.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Yield Strength /MPa | Tensile Strength /MPa | Elongation /% |
---|---|---|
86.2 | 159.6 | 25.4 |
Measuring Point | 0 | 1 | 2 | 3 | 4 | 5 | 6 | |
---|---|---|---|---|---|---|---|---|
Thickness (mm) | CDD | 6.80 | 6.76 | 6.70 | 6.62 | 6.52 | 6.50 | 6.64 |
3.7 MPa | 7.16 | 7.10 | 6.98 | 6.86 | 6.80 | 6.78 | 6.90 | |
5.2 MPa | 7.20 | 7.14 | 7.02 | 6.92 | 6.88 | 6.84 | 6.94 | |
Thickness thinning rate (%) | CDD | 9.3 | 9.9 | 10.7 | 11.7 | 13.1 | 13.3 | 11.5 |
3.7 MPa | 4.5 | 5.3 | 6.9 | 8.5 | 9.3 | 9.6 | 8.0 | |
5.2 MPa | 4.0 | 4.8 | 6.4 | 7.7 | 8.3 | 8.8 | 7.5 |
Measuring Point | 0 | 1 | 2 | 3 | 4 | 5 | 6 | |
---|---|---|---|---|---|---|---|---|
Normal strain | CDD | −0.098 | −0.104 | −0.113 | −0.125 | −0.140 | −0.143 | −0.122 |
3.7 MPa | −0.046 | −0.055 | −0.072 | −0.089 | −0.098 | −0.101 | −0.083 | |
5.2 MPa | −0.041 | −0.049 | −0.066 | −0.080 | −0.086 | −0.092 | −0.078 | |
Circumferential strain | CDD | 0.058 | 0.058 | 0.049 | 0.046 | 0.044 | 0.028 | −0.007 |
3.7 MPa | 0.020 | 0.020 | 0.034 | 0.036 | 0.025 | 0.006 | −0.017 | |
5.2 MPa | 0.020 | 0.020 | 0.030 | 0.033 | 0.020 | 0.004 | −0.020 | |
Radial strain | CDD | 0.040 | 0.046 | 0.064 | 0.079 | 0.096 | 0.115 | 0.128 |
3.7 MPa | 0.027 | 0.035 | 0.037 | 0.053 | 0.073 | 0.095 | 0.100 | |
5.2 MPa | 0.021 | 0.029 | 0.037 | 0.048 | 0.066 | 0.088 | 0.098 |
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Mo, C.; Xu, Y.; Yuan, S. Analysis of Thickness Variation in 2219 Aluminum Alloy Ellipsoid Shell with Differential Thickness by Hydroforming. Metals 2024, 14, 1140. https://doi.org/10.3390/met14101140
Mo C, Xu Y, Yuan S. Analysis of Thickness Variation in 2219 Aluminum Alloy Ellipsoid Shell with Differential Thickness by Hydroforming. Metals. 2024; 14(10):1140. https://doi.org/10.3390/met14101140
Chicago/Turabian StyleMo, Chen, Yongchao Xu, and Shijian Yuan. 2024. "Analysis of Thickness Variation in 2219 Aluminum Alloy Ellipsoid Shell with Differential Thickness by Hydroforming" Metals 14, no. 10: 1140. https://doi.org/10.3390/met14101140