Finite element simulation of SPF/DB process for ZK60 magnesium alloy corrugated part

Superplastic forming and diffusion boding (SPF/DB) technology has been considered as one of the advanced manufacturing methods. In this paper, SPF/DB process of magnesium alloy corrugated part was analyzed by FEM software (MARC) with three-dimensional finite element model. Penalty function method was applied to analyze the contact problem. The distribution of the wall-thickness and the deformation characteristic during the forming process were analyzed, and also, the location of the risky point was predicted by tracing the wall thickness and analyzing the friction between the die and the part. A ZK60 magnesium alloy corrugated part was produced successfully by SPF/DB, and the results of FEM simulation were in good agreement with that of the experiment. Meanwhile, it is observed that the cavities are growing with the increasing of the deformation amount, and the cavity size and percentage get maximum values (9μm and 7.7% respectively) at the corner region of the part, in which the wall-thickness decreases sharply and thereby leading to the fracture of the part.