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<p>As a typical high strain rate forming technology, impact hydroforming has shown many advantages in sheet metal forming, but there are few researches in the field of tube forming. In this paper, the deformation behavior of 5052 aluminum alloy tubes under impact hydroforming loading was studied. The quasi-static and high strain rate tensile experiments were carried out to obtain the tensile curves of 5052 aluminum alloy at the wide strain rates. The finite element simulation of the impact hydroforming process was carried out by means of solid-liquid coupling. The impact hydroforming process of the tube under different L/B (L is the tube length, B is the tube forming area length) was studied. The results show that the deformation behavior of the tube with small L/B is nonuniform, while the deformation behavior of the tube with large L/B is uniform. The tube crack limit diagram of impact hydroforming was obtained experimentally. When L/B = 1.2, the maximum energy required for tube cracking was 3.865&#xa0;kJ. As L/B increases, the maximum energy of tube cracking decreases significantly and fluctuates around 3 kJ. Due to the difference in deformation behavior, the maximum bulging diameter of the tube with large L/B is smaller than that of the tube with small L/B, but the maximum thinning rate is opposite. The study can provide the forming limit diagram and reference for the impact hydroforming of complex tubes.</p>

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Study on Forming Performance and Deformation Behavior of Impact Hydroforming of Aluminum Alloy Tubes

  • 期刊论文

  • 发表日期：

    2025年9月18日

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  • Wenlong Xie,
  • Yong Xu,
  • Xiangcheng Zeng,
  • Liangliang Xia,
  • Shi-Hong Zhang

摘要

As a typical high strain rate forming technology, impact hydroforming has shown many advantages in sheet metal forming, but there are few researches in the field of tube forming. In this paper, the deformation behavior of 5052 aluminum alloy tubes under impact hydroforming loading was studied. The quasi-static and high strain rate tensile experiments were carried out to obtain the tensile curves of 5052 aluminum alloy at the wide strain rates. The finite element simulation of the impact hydroforming process was carried out by means of solid-liquid coupling. The impact hydroforming process of the tube under different L/B (L is the tube length, B is the tube forming area length) was studied. The results show that the deformation behavior of the tube with small L/B is nonuniform, while the deformation behavior of the tube with large L/B is uniform. The tube crack limit diagram of impact hydroforming was obtained experimentally. When L/B = 1.2, the maximum energy required for tube cracking was 3.865 kJ. As L/B increases, the maximum energy of tube cracking decreases significantly and fluctuates around 3 kJ. Due to the difference in deformation behavior, the maximum bulging diameter of the tube with large L/B is smaller than that of the tube with small L/B, but the maximum thinning rate is opposite. The study can provide the forming limit diagram and reference for the impact hydroforming of complex tubes.