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<p>The forming technology of variable cross-section tube fittings is widely used in the field of mechanical manufacturing. However, the room temperature forming of a large-sized variable cross-section tube based on aluminum alloy materials is prone to cracking, which affects the final forming dimensional accuracy. The purpose of the paper is to explore the forming scheme and the deformation characteristics of variable cross-section AA5052-O aluminum alloy tubes. Based on electrohydraulic forming technology with the auxiliary hole, the influence of different discharge energies on the forming effect of tubes was studied. Firstly, the influence of discharge parameters on the attaching-die characteristic was explored through experiments. It was found that the optimal discharge parameter was 5&#xa0;kJ. Subsequently, the arbitrary Lagrangian-Euler (ALE) algorithm and fluid structure coupling were considered to establish an accurate prediction model. The accuracy of the prediction model was verified from the perspective of the attaching-die characteristic by comparing the errors of experiments and simulation models. The maximum radial deformation error is 1.6%, and the axial deformation error is 4.17%. Finally, the characteristics of complex deformation history were described with the help of predictive models. It aims to provide an application reference for the complex tube forming technology of aluminum alloy at room temperature.</p>

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Modeling and analysis for electrohydraulic forming of the variable cross-section tube with an auxiliary hole

  • 期刊论文

  • 发表日期：

    2025年11月29日

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  • Shanshan Chen,
  • Da Cai,
  • Wei Wei,
  • Linhua Yang,
  • Hao Jiang,
  • Junjia Cui,
  • Guangyao Li

摘要

The forming technology of variable cross-section tube fittings is widely used in the field of mechanical manufacturing. However, the room temperature forming of a large-sized variable cross-section tube based on aluminum alloy materials is prone to cracking, which affects the final forming dimensional accuracy. The purpose of the paper is to explore the forming scheme and the deformation characteristics of variable cross-section AA5052-O aluminum alloy tubes. Based on electrohydraulic forming technology with the auxiliary hole, the influence of different discharge energies on the forming effect of tubes was studied. Firstly, the influence of discharge parameters on the attaching-die characteristic was explored through experiments. It was found that the optimal discharge parameter was 5 kJ. Subsequently, the arbitrary Lagrangian-Euler (ALE) algorithm and fluid structure coupling were considered to establish an accurate prediction model. The accuracy of the prediction model was verified from the perspective of the attaching-die characteristic by comparing the errors of experiments and simulation models. The maximum radial deformation error is 1.6%, and the axial deformation error is 4.17%. Finally, the characteristics of complex deformation history were described with the help of predictive models. It aims to provide an application reference for the complex tube forming technology of aluminum alloy at room temperature.