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<p>Superplastic forming technology exhibits broad application prospects in the manufacturing of aluminum alloy components, with advantages including high dimensional accuracy, low residual stresses, and minimal rebound, it enables substantial weight reduction without compromising strength while even enhancing stiffness. However, formed components still face challenges such as uneven wall thickness and cracking. This paper analyses the rheological behavior of 5083 aluminum alloy plates at temperatures of 470&#xa0;°C, 490&#xa0;°C, and 510&#xa0;°C and strain rates of 0.01&#xa0;s⁻¹, 0.004&#xa0;s⁻¹, 0.0075&#xa0;s⁻¹, and 0.0006&#xa0;s⁻¹. Using ABAQUS software, numerical simulations of superplastic forming for 5083 aluminum alloy cup shell were conducted. To maximize the thinning rate of cup shell parts, response surface methodology was employed to perform numerical simulations of their preforming process, revealing the relationship between superplastic forming process parameters and the minimum thickness of cup shell, yielding the optimal combination of superplastic forming process parameters for 5083 aluminum alloy; furthermore, the forming height under varying rated pressures was analyzed, and forming tests were conducted using the optimal parameters to verify the accuracy of the experimental and simulation results. Finally, mechanical property evaluations at different locations of formed components were performed via tensile and hardness testing, while microstructural characterization was carried out via electron backscatter diffraction (EBSD). Results indicated that the superplastic forming cup shell parts demonstrating uniformly refined microstructures and high forming quality. These findings offer critical insights for manufacturing more complex aluminum alloy superplastic forming prats in aerospace and transportation industries.</p> Graphical abstract <p></p>

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Al5083 alloy cup shell finite element simulation and forming performance in superplastic forming process

  • 期刊论文

  • 发表日期：

    2025年11月13日

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  • Ge Yu,
  • Ye Liu,
  • Yi Li,
  • Xin Li,
  • Ziming Tang,
  • Wenping Yang

摘要

Superplastic forming technology exhibits broad application prospects in the manufacturing of aluminum alloy components, with advantages including high dimensional accuracy, low residual stresses, and minimal rebound, it enables substantial weight reduction without compromising strength while even enhancing stiffness. However, formed components still face challenges such as uneven wall thickness and cracking. This paper analyses the rheological behavior of 5083 aluminum alloy plates at temperatures of 470 °C, 490 °C, and 510 °C and strain rates of 0.01 s⁻¹, 0.004 s⁻¹, 0.0075 s⁻¹, and 0.0006 s⁻¹. Using ABAQUS software, numerical simulations of superplastic forming for 5083 aluminum alloy cup shell were conducted. To maximize the thinning rate of cup shell parts, response surface methodology was employed to perform numerical simulations of their preforming process, revealing the relationship between superplastic forming process parameters and the minimum thickness of cup shell, yielding the optimal combination of superplastic forming process parameters for 5083 aluminum alloy; furthermore, the forming height under varying rated pressures was analyzed, and forming tests were conducted using the optimal parameters to verify the accuracy of the experimental and simulation results. Finally, mechanical property evaluations at different locations of formed components were performed via tensile and hardness testing, while microstructural characterization was carried out via electron backscatter diffraction (EBSD). Results indicated that the superplastic forming cup shell parts demonstrating uniformly refined microstructures and high forming quality. These findings offer critical insights for manufacturing more complex aluminum alloy superplastic forming prats in aerospace and transportation industries.

Graphical abstract