Formation of aluminum-magnesium alloy cup by hydrodynamic deep drawing with twin-loading paths

In order to overcome the limitation of hydro-rim deep drawing, a new process of hydrodynamic deep drawing (HDD) with independent radial hydraulic pressure was proposed. By employing the dynamic explicit analytical software ETA/Dynaform5.5 which is based on LS-DYNA3D, the effects of independent radial hydraulic pressure on the stress, strain and the sheet-thickness of aluminum-magnesium cylindrical cup with a hemispherical bottom were analyzed by numerical simulation. The feature of stress distribution is that there exists a stress-dividing circle in the flange, and the radius of dividing circle was determined by theoretical analysis and stimulation. The experimental results indicate that the reasonable match of independent radial hydraulic pressure and liquid chamber pressure can effectively reduce the thinning at the bottom of hemisphere, decrease the radial stress-strain, and improve the drawing limit of aluminum-magnesium alloy cylindrical cup. Funded by the National Natural Science Foundation of China (Nos.50525516, 50875062)