Superplastic Forming of Triangular Channels with Sharp Radii

The superplastic forming process is used to form light weight components with complex features in one manufacturing step. However, the non-uniformity of the produced part thickness and the possibility of severe thinning are among its major disadvantages. The goal of this parametric study was to investigate feasible geometries for triangular channels to be manufactured by superplastic forming. The channels considered had sharp radii and served as secondary features extending along a circular path at the base of a shallow cup. An axisymmetric finite element model in ABAQUS? was used to simulate the forming process. Effects of the aspect ratios of both the cup and the triangular channel on the thickness distribution and the pressure profiles were investigated. An experimental setup was used for validating the simulation results for AA5083 at 500 °C.