Numerical simulation of aluminum alloy conical cup forming by Hydro-mechanical deep drawing

Based on large height-diameter ratio parts forming needs, a new process of Hydro-mechanical deep drawing with independent radial pressure was proposed. Aiming at the 5A06 thin-walled aluminum alloy conical cup, the influence of hydraulic loading paths and radial pressure reasonable matching relations on wall-thickness distribution were discussed and studied by means of numerical simulation. The stress state of deformation zone, the wrinkling of suspended deformation area and the crack of cone bottom were analyzed. The results indicate that the reasonable match of liquid chamber pressure and independent radial pressure can effectively restrain the occurring of crack at the cone bottom and inner-wrinkling defects at the conical-wall area of the part, increase the forming limitation and improve the wall-thickness distribution uniformity and forming quality in the forming process.