Investigation on the forming of automotive component with AA6016 aluminum alloy based on the fluid-solid sequence coupling technology

In this paper, a kind of flow-solid sequence coupling technology for forming large aluminum alloy automotive covering parts was presented. Firstly, the numerical simulation of hydraulic bulging process was carried out. Then, the springback analysis and mold surface compensation for the simulation results were implemented. The hydraulic bulging test was made by using the optimized compensation surfaces of mold, and the hydraulic bulging parts with relatively accurate shape were obtained. The accuracy of the numerical simulation results was verified by comparing the experimental values and simulation values of the 3D deviation on the same measurement paths; then, in order to form the small fillet features in three different areas of the part, the numerical simulation and experiment research of the stamping technology were carried out on the part obtained by the hydraulic bulging process. The accuracy of the numerical simulation results was verified by comparing the experimental values and simulation values of the thickness distribution on the measurement path; finally, using the numerical simulation of fluid-solid sequence coupling forming process and the matching experiment, the changing rules of the first principal strain and the second principal strain in the small features were studied from the angle of the qualitative and quantitative analysis and it was fully verified that the small characteristics have deformed sufficiently at the end of local shaping process with the rigid die.