Finite element analysis and experimental investigation on gas forming of hot aluminum alloy sheet

Aluminum alloys are desirable in industry due to their excellent high-strength to weight ratio, corrosion resistance, and weldability. However, at room temperature, the formability and the surface quality of the final product of these alloys are low. So in recent decade, new process, hot metal gas forming, has been introduced. This paper investigated new method of hot aluminum alloys forming using gas. Experimental test for bulge forming was designed and made. In addition to experimental test, finite element analysis of process was done. Results showed that hot metal gas forming provides highest forming temperature for aluminum alloy blank and with increasing blank temperature up to optimum temperature of hot forming, there is reduced pressure forming and significant improvement of formability. Results of experimental test and finite element analysis including determination of optimum temperature for forming of special aluminum alloy, maximum formability in this process, required forming pressure, minimum thickness, thickness and temperature distribution were conformed.