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<p>Achieving uniform thickness in superplastic forming (SPF) of hemispherical domes is a critical challenge, typically addressed by using complex, nonlinear variable-thickness blanks. However, manufacturing such profiles is often cost-prohibitive. This study proposes a cost-effective alternative: a truncated-cone blank profile, easily manufacturable via conventional CNC machining. Compared to complex, non-linear, variable-thickness profiles, which require continuous multi-axis interpolation and long cycle times, the proposed linear configuration reduces CNC machining time, drastically cutting pre-forming manufacturing costs. A hybrid approach combining analytical modeling and Finite Element Method (FEM) was employed to optimize the blank geometry. The analytical model provided a preliminary "coarse" design and identified the limitations of assuming equal pole-to-edge thickness. Subsequently, FEM simulations were used for the "fine-tuning" of the geometric parameters (<i>α</i>, <i>S</i><sub><i>max</i></sub>, <i>S</i><sub><i>min</i></sub>). The study demonstrates that while a constant-thickness blank results in a severe thickness reduction, the optimized truncated-cone profile (<i>α</i> = 0.2) dramatically improves uniformity. The numerical predictions were validated experimentally using an AZ31 Magnesium alloy, confirming the superior formability and geometric accuracy of the proposed profile. The research proves that the truncated-cone profile offers the optimal trade-off between manufacturing simplicity and final product quality, providing a viable industrial solution for SPF components.</p>

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Cost-effective thickness optimization in superplastic forming of hemispherical domes via truncated-cone blanks: a hybrid analytical–numerical approach

  • 期刊论文

  • 发表日期：

    2026年7月16日

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  • Gillo Giuliano,
  • Wilma Polini

摘要

Achieving uniform thickness in superplastic forming (SPF) of hemispherical domes is a critical challenge, typically addressed by using complex, nonlinear variable-thickness blanks. However, manufacturing such profiles is often cost-prohibitive. This study proposes a cost-effective alternative: a truncated-cone blank profile, easily manufacturable via conventional CNC machining. Compared to complex, non-linear, variable-thickness profiles, which require continuous multi-axis interpolation and long cycle times, the proposed linear configuration reduces CNC machining time, drastically cutting pre-forming manufacturing costs. A hybrid approach combining analytical modeling and Finite Element Method (FEM) was employed to optimize the blank geometry. The analytical model provided a preliminary "coarse" design and identified the limitations of assuming equal pole-to-edge thickness. Subsequently, FEM simulations were used for the "fine-tuning" of the geometric parameters (α, Smax, Smin). The study demonstrates that while a constant-thickness blank results in a severe thickness reduction, the optimized truncated-cone profile (α = 0.2) dramatically improves uniformity. The numerical predictions were validated experimentally using an AZ31 Magnesium alloy, confirming the superior formability and geometric accuracy of the proposed profile. The research proves that the truncated-cone profile offers the optimal trade-off between manufacturing simplicity and final product quality, providing a viable industrial solution for SPF components.