Optimization of the combined process of deep-drawing and gas-forming by Taguchi method for producing cubic parts from AA5083 alloy

Aluminum alloys have become widespread in the various industries due to the characteristic of high strength-to-density ratio. These alloys do not have a suitable formability at ambient temperature so they formed at high temperatures. The main hot forming methods used for aluminum alloys include deep drawing and gas forming. Both of these methods have their own advantages and disadvantages. In this study, a combined process involving deep drawing and gas forming has been used. In this process, the first step is to create a pre-formed deep drawing and in the second stage, the final piece is produced by gas forming process. The purpose of this study is to optimize the levels of the main process parameters for the shaping of cubic parts of aluminum sheet 5083 sheet. These parameters include the temperature and blank-holder force of deep drawing stage and the temperature and gas pressure at the gas forming stage. The best levels of process parameters were selected using the Taguchi experimental design method. The results show that the temperature at 350 ° C and the blank-holder force of 1000 N for deep drawing, as well as the temperature of 485 ° C and the gas pressure of 0.6 MPa for the gas forming stage, can be achieved with the least degree of thinning in the specimen. The maximum thinning achieved is 22%.