Research on Hydroforming of 2219 Aluminum Alloy Plate with Differential Thickness
In view of the problems of easy cracking and large amount of machining in the spinning and machining of heavy plates,a deep drawing forming method of a plate with differential thickness was proposed to manufacture an integral dome of the propellant tank in carrier rocket.The circular aluminum alloy plate has a smaller thickness in the middle and a larger thickness in the periphery.During the deformation process of such plates,the thin zone is prone to rupture defects.In order to solve this problem,the hydroforming method in coupling with an elastic auxiliary plate was adopted.Through numerical simulation and deep drawing experiments,the effects of hydraulic pressure and elastic auxiliary plate on the distributions of thickness and strain of plates with differential thickness were studied.The results show that increasing the hydraulic pressure and setting the elastic auxiliary plate can increase the interfacial friction,reduce the maximum thickness thinning rate of the drawn ellipsoid shell,and improve the thickness distribution within the thin zone.When the hydraulic pressure is 5.2 MPa and the thickness of the elastic auxiliary plate is 5 mm,the maximum thickness thinning rate of the ellipsoid shell is 8.8％,which is 34％lower than that of the ellipsoid shell obtained via conventional deep drawing.
2219 aluminum alloyhydro formingdifferential thickness platethickness distribution
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