On the thickness distribution and the maximum thinning ratio in hydrostatic forming for sheet metal

Abstract

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.