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Optimization of process parameters to enhance formability of AA 5182 alloy in deep drawing of square cups by hydroforming

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Abstract

The formability of 1 mm thick AA5182 aluminum alloy sheets in deep drawing of square cups by hydroforming was studied. The influence of process parameters (peak pressure, pressure path, and blank holding force) on formability was investigated through numerical simulations and validated with experimental work. The experiments were designed using the Taguchi method. The minimum thickness in the formed cups (at the bottom corners) and the minimum corner radius that can be achieved were considered as the criteria for evaluation of formability. The peak pressure was the most important process parameter affecting thinning and the minimum corner radius that can be achieved. The variation of the pressure path had the least effect on formability. Regression models were developed for prediction of minimum thickness in the cup and the corner radius as a function of peak pressure and blank holding force.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology, Delhi, India

    Bharatkumar Modi & D. Ravi Kumar

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  1. Bharatkumar Modi
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  2. D. Ravi Kumar
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Correspondence to D. Ravi Kumar.

Additional information

Recommended by Associate Editor Young Whan Park

Bharatkumar Modi was a research scholar in the Department of Mechanical Engineering, Indian Institute of Technology Delhi, India when this work was carried out. He is presently a Professor of Mechanical Engineering, Nirma University, Ahmedabad, India.

D. Ravi Kumar is a Professor of Mechanical Engineering, Indian Institute of Technology Delhi, India. His research interests include sheet metal forming, finite element analysis, hydroforming, lightweight materials and severe plastic deformation techniques.

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Modi, B., Kumar, D.R. Optimization of process parameters to enhance formability of AA 5182 alloy in deep drawing of square cups by hydroforming. J Mech Sci Technol 33, 5337–5346 (2019). https://doi.org/10.1007/s12206-019-1026-2

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  • DOI: https://doi.org/10.1007/s12206-019-1026-2

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