Numerical simulation and experimental study of warm hydro-forming of magnesium alloy sheet

The uneven forming temperature during warm hydro-forming of magnesium alloy sheets is one of the main causes of defects in formed parts. In order to completely solve this problem to obtain products with good forming quality, a new warm forming method for magnesium alloy sheet is proposed: the magnesium alloy sheets and forming die are immersed in hot oil to achieve constant temperature forming. In addition, a hot oil warm hydro-forming device for magnesium alloy sheets was designed and developed. This work also carried out the numerical simulations and forming experiments, this study to investigated the effects of forming concave die chamfer, temperature, friction coefficient, hydraulic pressure, and blank holder force on the warm hydro-forming of magnesium alloy sheet. The simulation results are in good agreement with the experimental ones, and the feasibility of warm hydro-forming of magnesium alloy sheet is verified. According to the numerical simulations and forming experiments, the best process window for warm hydro-forming of l mm thick AZ31B magnesium alloy sheet was obtained. The hot oil constant temperature hydraulic forming technology can enrich the forming process of magnesium alloy and provide a new perspective and technical basis for warm forming of other hard-to-deform metal materials.