The Forming Limit Diagram of 2A16 Aluminum Alloy Sheet Based on Hydraulic Bulging Test of Elliptical Die

¹ Beihang University, School of Mechanical Engineering and Automation, 100191 Beijing, China
² Xiaomi Corporation, Hardware Engineering Department, 100191 Beijing, China
³ Aviation Industry Xi’an Aircraft Industry (Group) Co., Ltd., Sheet Metal Department, 710089 Xi’an, China

^* Corresponding author: liyong19@buaa.edu.cn

Abstract

An elliptical die hydraulic bulging test was carried out to explore the forming performance of 2A16 aluminum alloy sheets during hydroforming. By using five groups of elliptical dies with ovality of 1.0, 0.9, 0.8, 0.6, and 0.4, the effects of different pressure rates of 0.02 MPa/s, 0.04 MPa/s, and 0.08 MPa/s on the test results were studied, and different sheets thicknesses of 2 mm and 2.5 mm were also explored, then the equivalent stress and strain values obtained by theoretical calculation were also analyzed. Finally, the complete forming limit diagram (FLD) of the 2A16 aluminum alloy sheet at room temperature was plotted through the elliptical hydraulic bulging test and the uniaxial tensile test under the same test conditions. The results show that as the ellipticity increases, the maximum equivalent stress-strain value of sheets gradually increases; reducing the hydroforming pressure rate or increasing the thickness of the sheet can slightly increase the maximum bulging height of the sheet, but it has no significant impact on the maximum equivalent stress and strain value of this material. There is no noticeable difference in the FLD on the right side, indicating that its FLD is universal for a material.