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<p>This study systematically investigates the defect types and formation mechanisms in filler-free press-bending forming of magnesium alloy panels. The mechanical characteristics of neutral layer migration during panel bending were theoretically analyzed, with quantitative evaluation of skin depression severity through differential analysis of neutral layer offset variations. Theoretical calculations demonstrated good agreement with experimental results. Under processing parameters of 75 mm die width and 9 mm pressing height, the neutral layer offset difference (Δ = 0.3863 mm) between ribbed regions and grid center regions was identified as the fundamental cause of surface depression defects. A novel rigid filler press-bending process was developed to effectively control neutral layer migration in grid center areas, achieving significant improvements in surface flatness and enhancing dimensional accuracy by over 200 %. When the gap was optimized to 12.5 % of the grid width, the resulting skin concavity was reduced to merely 1.1222 % of the wall panel thickness.</p>

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Mechanical characteristics of the neutral layer and skin surface flatness in rigid-filled press-bending forming of magnesium alloy panels

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Yuqi Xin,
  • Quan Liu,
  • Zhongtang Wang,
  • Chunxin Wang,
  • Yanjuan Li,
  • Haicheng Liang

摘要

This study systematically investigates the defect types and formation mechanisms in filler-free press-bending forming of magnesium alloy panels. The mechanical characteristics of neutral layer migration during panel bending were theoretically analyzed, with quantitative evaluation of skin depression severity through differential analysis of neutral layer offset variations. Theoretical calculations demonstrated good agreement with experimental results. Under processing parameters of 75 mm die width and 9 mm pressing height, the neutral layer offset difference (Δ = 0.3863 mm) between ribbed regions and grid center regions was identified as the fundamental cause of surface depression defects. A novel rigid filler press-bending process was developed to effectively control neutral layer migration in grid center areas, achieving significant improvements in surface flatness and enhancing dimensional accuracy by over 200 %. When the gap was optimized to 12.5 % of the grid width, the resulting skin concavity was reduced to merely 1.1222 % of the wall panel thickness.