Research on plastic flow behaviors for hole flanging part of aluminum alloy with large complicated profiles by electromagnetic forming

Hole flanging part of aluminum alloy with large complicated profiles by electromagnetic forming is a complex metal forming process coupling electromagnetic field and constructive field. Due to the effects of large complicated profiles, plastic flow behaviors during the forming process are different from traditional flanging forming. A finite element model for hole flanging part of aluminum alloy with large complicated profiles by electromagnetic forming is established based on loose coupling simulation method, and then plastic flow behaviors on condition of one layer flat coil, two layers flat coil and three layer flat coil are investigated, and subsequently plastic flow rules of flange parts under different pressures are revealed by experiments. The results are as follows: Large complicated profiles are completed closed to female die surfaces on condition of three layer flat coil, flange parts are put into female die and plastic flow phenomenon is more obvious; flange parts are grown to different modes under different pressures, and obvious wrinkling phenomenon for flange parts appear when pressures are less; hole flanging part of aluminum alloy with large complicated profiles more closed to female die surfaces is obtained by controls of reasonable pressures. © 2013 Journal of Mechanical Engineering.