An elliptical warm/hot sheet bulging test under different temperatures and pressure rates was carried out to predict Al-alloy sheet forming limit during warm/hot sheet hydroforming. Using relevant formulas of ultimate strain to calculate and dispose experimental data, forming limit curves (FLCS) in tension–tension state of strain (TTSS) area are obtained. Combining with the basic experimental data obtained by uniaxial tensile test under the equivalent condition with bulging test, complete forming limit diagrams (FLDS) of Al-alloy are established. Using a quadratic polynomial curve fitting method, material constants of fitting function are calculated and a prediction model equation for sheet metal forming limit is established, by which the corresponding forming limit curves in TTSS area can be obtained. The bulging test and fitting results indicated that the sheet metal FLCS obtained were very accurate. Also, the model equation can be used to instruct warm/hot sheet bulging test.
Warm/hot sheet bulging tests of 2A16-O aluminum alloy were conducted using elliptical bulging dies under various temperatures and pressure rates, in an effort to investigate the macroscopic and microscopic influence of the pressure rate on the formability and microstructural evolution of hydrobulging parts during warm/hot sheet hydroforming. The results revealed that the forming limit of the aluminum alloy was clearly influenced by the pressure rate as the temperature rose, wherein a lower pressure rate resulted in a higher forming limit. Metallographic observations and Energy Dispersive Spectrometer (EDS) analysis revealed no obvious influence of the pressure rate on the microstructure of hydrobulging parts after warm/hot sheet hydroforming. This study demonstrates that warm/hot sheet hydroforming of aluminum alloy may lead to an improved forming limit and inhibit microstructural degradation during processing.
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