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<p>To address the poor room-temperature plasticity and difficulty in forming complex components of AZ31B magnesium alloy, this study investigates its multi-pass double-sided incremental forming process under heated conditions, focusing on the influence of gradient strategies for key inter-pass parameters on forming quality. By establishing an ABAQUS finite element model combined with experimental validation, the effects of heating temperature (150–250&#xa0;°C) and forming modes were systematically analyzed, and gradient designs of three parameters—forming angle, axial spacing, and tool radius—were compared. The results show that support forming at 250&#xa0;°C is the optimal baseline process. The gradient of the pass forming angle has the most significant impact: an increasing angle sequence (45°–55°–70°) helps improve wall thickness uniformity, while a decreasing angle sequence (45°–60°–70°) is more conducive to dimensional accuracy. Increasing axial spacing (0.5–1.0–1.5&#xa0;mm) enhances overall wall thickness, and increasing tool radius (3–4–5&#xa0;mm) improves forming accuracy. Orthogonal experiments indicate the optimal combinations for maximizing minimum wall thickness (M1V3N1) and dimensional accuracy (M3N2V2). This research provides theoretical and practical guidance for parameter gradient optimization in heated multi-pass double-sided incremental forming of AZ31B magnesium alloy.</p>

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Heated double-sided incremental forming of AZ31B magnesium alloy based on pass parameter gradient design: wall thickness distribution and accuracy control

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Chunjian Su,
  • Yun Mi,
  • Lingao Zhang,
  • Qinglin Li,
  • Yansheng Zang,
  • Xiang Meng,
  • Congjie Wei,
  • Changting Xu,
  • Yuepeng Ma,
  • Kai Zhang

摘要

To address the poor room-temperature plasticity and difficulty in forming complex components of AZ31B magnesium alloy, this study investigates its multi-pass double-sided incremental forming process under heated conditions, focusing on the influence of gradient strategies for key inter-pass parameters on forming quality. By establishing an ABAQUS finite element model combined with experimental validation, the effects of heating temperature (150–250 °C) and forming modes were systematically analyzed, and gradient designs of three parameters—forming angle, axial spacing, and tool radius—were compared. The results show that support forming at 250 °C is the optimal baseline process. The gradient of the pass forming angle has the most significant impact: an increasing angle sequence (45°–55°–70°) helps improve wall thickness uniformity, while a decreasing angle sequence (45°–60°–70°) is more conducive to dimensional accuracy. Increasing axial spacing (0.5–1.0–1.5 mm) enhances overall wall thickness, and increasing tool radius (3–4–5 mm) improves forming accuracy. Orthogonal experiments indicate the optimal combinations for maximizing minimum wall thickness (M1V3N1) and dimensional accuracy (M3N2V2). This research provides theoretical and practical guidance for parameter gradient optimization in heated multi-pass double-sided incremental forming of AZ31B magnesium alloy.