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<p>This paper presents formability tests on aluminum alloys using asymmetric dies under two electrohydraulic forming methods. The first method is conventional electrohydraulic forming (EHF), where a single high-voltage pulse is applied to deform a flat blank into an irregular die cavity. The second method adopts a two-stage approach: an initial stamping preform using a flexible punch partially fills the die cavity, followed by electrohydraulic flexible punch forming (EFPF) to complete the forming process. Experimental results demonstrate that the proposed two-stage process significantly improves formability in asymmetric dies, with the major and minor strains at the top region of the deformed sheet increasing by 20.8% and 12.2%, respectively. In addition, a multiphysics numerical simulation model was developed to analyze sheet deformation behavior in both forming methods. Simulation results indicate that the two-stage process enables efficient pressure transmission and enhances formability in difficult-to-shape regions. The predicted maximum strain rates for EHF and EFPF were 10,646&#xa0;s⁻¹ and 7966&#xa0;s⁻¹, respectively, confirming that both methods exhibit characteristics of high strain rate forming. Moreover, the two-stage flexible punch forming method not only reduces the severity of maximum thinning but also decreases the maximum thickness reduction rate to 23.1%.</p>

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Enhancing formability in electrohydraulic forming of aluminum alloys with asymmetric dies via a Two-Stage flexible punch approach

  • 期刊论文

  • 发表日期：

    2025年12月3日

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  • Longhui Lu,
  • Wenfei Peng,
  • Xiaowen Tu,
  • Xiaoqian Pan,
  • Yiyu Shao,
  • Shenghong Xue

摘要

This paper presents formability tests on aluminum alloys using asymmetric dies under two electrohydraulic forming methods. The first method is conventional electrohydraulic forming (EHF), where a single high-voltage pulse is applied to deform a flat blank into an irregular die cavity. The second method adopts a two-stage approach: an initial stamping preform using a flexible punch partially fills the die cavity, followed by electrohydraulic flexible punch forming (EFPF) to complete the forming process. Experimental results demonstrate that the proposed two-stage process significantly improves formability in asymmetric dies, with the major and minor strains at the top region of the deformed sheet increasing by 20.8% and 12.2%, respectively. In addition, a multiphysics numerical simulation model was developed to analyze sheet deformation behavior in both forming methods. Simulation results indicate that the two-stage process enables efficient pressure transmission and enhances formability in difficult-to-shape regions. The predicted maximum strain rates for EHF and EFPF were 10,646 s⁻¹ and 7966 s⁻¹, respectively, confirming that both methods exhibit characteristics of high strain rate forming. Moreover, the two-stage flexible punch forming method not only reduces the severity of maximum thinning but also decreases the maximum thickness reduction rate to 23.1%.