A novel impact hydroforming press for forming aviation complex thin wall aluminum sheet metal part

DOI:	10.11809/bqzbgcxb2023.10.010
Keywords:	hydroforming; high speed forming; aviation sheet metal part; aluminum
Abstract:	A novel impact hydroforming (IHF) press is proposed in this paper, which combines the advantages of hydroforming (HF) and high speed forming. IHF has many advantages such as improving the plasticity of metals, reducing spring back, no need for sealing, good surface quality, and the ability to form small size features. IHF is able to solve the problems such as wrinkling, crack and needs lots of manual assistance encountered in the traditional drop press forming. First, the load propagation characteristics of the shock wave produced by the impact are experimentally investigated. There are two kinds of impact forms: single and double projectile. The liquid chamber pressure maintaining ability, the liquid solid interface pressure doubly factor, and the energy utilization rate of the large mass single projectile are better. An IHF equipment is designed and manufactured with a novel gas liquid combined high pressure driven principle. The impact energy is 225 kJ, the liquid chamber diameter is 250 mm, the peak dynamic pressure is larger than 1 000 MPa. This IHF press is able to be used in industrial manufacture which is different from the previous setups mainly used to do research. A 5A06 aluminum alloy complex thin wall aero frame sheet part is used to verify the IHF technology and equipment. The production process is reduced to only 2 steps of automatic forming from 7 to 8 steps of traditional drop press forming, the manufacturing efficiency is increased by more than 4 times and successfully solved the wrinkling and the crack problem.
Issue:	Vol. 44 No. 10 (2023)
Published:	2023-10-28
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