A novel hybrid hot forming process concept for high strength aluminum alloys
Naveen K. Baru, Tobias Teeuwen, David Bailly, Emad Scharifi
Abstract. The present study focuses on the numerical and experimental feasibility of a novel hybrid hot forming process involving solution heat treatment and a combined deep drawing and gas-based forming for high strength aluminum alloys. For this, FE simulations are first carried out by establishing a numerical model of the hybrid forming process in order to identify the process parameters to ensure macroscopic failure-free forming of a complex-shaped cross-die and counteract on localized thinning. In addition, an integrated hybrid forming test setup is realized to form the cross-die specimen for validating the numerical predictions. The numerical parameter studies suggest a suitable initial blank size for forming the cross-die, and the influence of the blank holder force and the friction coefficient on the maximum thinning at the cross-die radii. The following forming experiments show a high dimensional accuracy after deep drawing and gas-based forming steps. Comparing the individual forming steps moreover reveals that a higher local thinning is introduced during the gas-based forming. Finally, the comparison between the simulation and the experimental results demonstrates a good agreement for local thinning.
Keywords
Metal Forming, Finite Element Method (FEM), Gas-Based Hot Forming
Published online 4/1/2025, 8 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Naveen K. Baru, Tobias Teeuwen, David Bailly, Emad Scharifi, A novel hybrid hot forming process concept for high strength aluminum alloys, Materials Research Proceedings, Vol. 52, pp 134-141, 2025
DOI: https://doi.org/10.21741/9781644903551-17
The article was published as article 17 of the book Sheet Metal 2025
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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