Forming of Hemispherical-Cylindrical Cups Using Hydrodynamic Deep Drawing Assisted by Radial Pressure

Due to the bad cold-formability of aluminum alloys in deep drawing process، many forming methods have been explored to increase the drawing ratio of these alloys. Sheet Hydro-Forming is one of the processes that can be used to the forming of cups with high drawing ratio from bad cold-formability materials. In this paper، the forming of AA6063-T4 aluminum alloy hemispherical-cylindrical cups by hydrodynamic deep drawing assisted by radial pressure were investigated experimentally and analyzed using finite element simulation. By examining several pressure paths، the effect of pressure path on bursting and thickness distribution of the sheet was studied. The results indicated that by using this process and applying an appropriate pressure path، the sound cups، with high drawing ratio and uniform thickness distribution could be formed in one stage. Also، in this paper by using FE simulation and Taguchi technique، a systematically method was developed to analyze the effects of the forming parameters on the quality of part formability and determine the optimal combination of the forming parameters for sheet Hydro-Forming process. The results of analysis indicated that fluid pressure has the greatest influence on the part formability in sheet Hydro-Forming process. And also by using rough punch، lower gap between die rim block and blank holder and greater die entrance radius the formability of sheet will be improved.