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Forming fluid pressure is an important technological parameter that determines whether a product can be accurately formed according to the size and profile of the die in hydrostatic forming technology. The expected value of this parameter is often very high because it acts as the punch in forming complex products from sheet metal. However, it is difficult to achieve high values because the forming fluid pressure depends on the ability to hold high pressure of equipment system and input parameters including the blank holder pressure, the depth of die, the thickness of workpiece. Moreover, it is also necessary to have a mathematical model for this parameter to facilitate the calculation and control of the forming process. In order to solve the above problems, this paper will indicate a simple way to avoid the pressure drop during forming process, and establish a regression function relationship between the forming fluid pressure for typical cylindrical product and input parameters above by experimental research method. The results contribute to die design, calculation and control of process parameters to facilitate shaping thin shell products in actual hydrostatic forming technology.

In manufacturing, thickness distribution and maximum thinning greatly affect product quality in sheet metal forming. They depend on many input parameters, such as technological parameters, geometric shape of die, workpiece’s materials and forming methods. Hydrostatic forming technology is particularly suitable for forming thin-shell products with complex shapes. However, due to the forming characteristics, the thinning phenomenon in this technology is much more intense than in other forming methods. Therefore, this study aims to determine the thickness distribution and the relationship between the maximum thinning ratio and input parameters including blank holder pressure, relative depth of the die and relative thickness of the workpiece in this technology. The chosen product shape is cylinder and the chosen method is the orthogonal second-order design. The results are expressed in graphs and functions and they can be applied in product design, calculation and control of input parameters in industrial manufacturing.

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