Numerical/experimental analysis of the sheet hydro forming process using cylindrical, square and compound shaped cavities

In this work, the authors focus the attention on the problems involved with the production of complex shapes using the sheet hydro forming (SHF) process adopting a numerical experimental approach. A specific in-home equipment has been used to perform tests on single sheet metal blanks. SHF tests with different die cavity shapes have been performed on circular blanks in AISI 304. The finite element (FE) technique has been adopted to perform the numerical analysis; experimental data have been used to both define and validate the FE model. Simulations of the SHF process applied to the production of cylindrical, squared and compound shaped parts have been undertaken. The feasibility and the main problems related to the forming operation of such shapes have been investigated through the analysis of the equivalent plastic strain (PEEQ) distribution and the strain paths of the most critical areas.