Analysis of bulging process of aluminum alloy by overlapping sheet metal and its formability

The influences of strength coefficient K, work hardening exponent n and thickness t of the overlapping sheet on bulging process are analyzed based on hardening material model. Also, bulging experiments are carried out by taking the aluminum alloy LF21 as formed sheet metal, and selecting overlapping sheet with different thicknesses and material properties, by which accuracy of the above analysis result is verified in the aspects of geometric shape, thickness distribution and limit bulging height. The results show that higher strength coefficient K, larger work hardening exponent n and proper thickness of the overlapping sheet are helpful to improve the formability and forming uniformity of formed sheet metal.