Investigation into hydrodynamic deep drawing assisted by radial pressure: Part II. Numerical analysis of the drawing mechanism and the process parameters

A new method, named hydrodynamic deep drawing assisted by radial pressure, is proposed. Different from the conventional hydrodynamic deep drawing process (HDD), a radial pressure is loaded along the blank rim to reduce the drawing force. To explore the internal deformation mechanism, the numerical simulation was used for analyzing the forming process of an Al–Mg–Si aluminum alloy by using explicit dynamic finite element calculations utilizing non-quadratic yield criteria. Firstly, the loading boundary conditions were studied for the purpose of calculating the forming process accurately. The effects of sheet anisotropy on the material flow velocity distribution, the stress distribution, the strain distribution and the sheet thickness distribution were investigated. The optimum parameters were studied so that the flange wrinkling and fracture can be predicted and controlled effectively. The simulated results were in good agreement with the experiment.