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<p>Air conditioning energy consumption constitutes approximately 60% of total building energy consumption. The efficacy and quality of aluminum fins can be significantly compromised by defects arising during the formation process of ultra-thin aluminum alloys, wherein high-performance heat exchangers serve as pivotal components. This study focuses on the mechanical behavior and forming simulation of ultra-thin 8011-H22 aluminum alloy. Distinct fracture modes emerge in ultra-thin 8011-H22 aluminum alloys of varying thicknesses, revealing notable variability. Moreover, tensile strength (TS) and elongation (EL) exhibit an inverse correlation with thickness, illustrating the phenomenon of “the smaller the weaker.” Leveraging the modified Johnson–Cook (MJC) model, the deformation behavior of ultra-thin 8011-H22 aluminum alloy is accurately predicted for thicknesses ranging from 0.1 to 0.5&#xa0;mm (<i>R</i> = 98.29% and <i>E</i><sub>AARE</sub> = 0.041). The reliability of the MJC model is indirectly validated through favorable simulation outcomes of the bulge surface. Following continuous process optimization, a final real sample is produced for trial, with the dimensional variance between the simulation and the actual sample falling below 3%. This comprehensive analysis of the mechanical behavior and forming simulation of ultra-thin 8011-H22 aluminum alloy is expected to provide a theoretical basis for the subsequent widespread application of ultra-thin sheet forming technology.</p>

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Study on Mechanical Behavior and Forming Simulation of Ultra-Thin 8011 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年2月17日

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  • Ping Li,
  • Renhai Yu,
  • Baishun Zhang,
  • Yang Wang,
  • Jie Chu,
  • Kemin Xue

摘要

Air conditioning energy consumption constitutes approximately 60% of total building energy consumption. The efficacy and quality of aluminum fins can be significantly compromised by defects arising during the formation process of ultra-thin aluminum alloys, wherein high-performance heat exchangers serve as pivotal components. This study focuses on the mechanical behavior and forming simulation of ultra-thin 8011-H22 aluminum alloy. Distinct fracture modes emerge in ultra-thin 8011-H22 aluminum alloys of varying thicknesses, revealing notable variability. Moreover, tensile strength (TS) and elongation (EL) exhibit an inverse correlation with thickness, illustrating the phenomenon of “the smaller the weaker.” Leveraging the modified Johnson–Cook (MJC) model, the deformation behavior of ultra-thin 8011-H22 aluminum alloy is accurately predicted for thicknesses ranging from 0.1 to 0.5 mm (R = 98.29% and EAARE = 0.041). The reliability of the MJC model is indirectly validated through favorable simulation outcomes of the bulge surface. Following continuous process optimization, a final real sample is produced for trial, with the dimensional variance between the simulation and the actual sample falling below 3%. This comprehensive analysis of the mechanical behavior and forming simulation of ultra-thin 8011-H22 aluminum alloy is expected to provide a theoretical basis for the subsequent widespread application of ultra-thin sheet forming technology.