Formability behaviors of 2A12 thin-wall part based on DYNAFORM and stamping experiment

A method integrating theoretical analysis, numerical simulation and experimental methods was adopted to solve the existing problems, including fillet less-plumping, cracks and wrinkling, in the forming process of a double curvature, thin-wall aluminum alloy part (DCTAP) of the aircraft skin. The mechanical properties of a 0.5 mm thick aluminum alloy sheet (2A12) were obtained through the uniaxial tensile test. The optimal blank holder force (BHF), blank shape (BS) and blank dimension (BD) were obtained by simulation using DYNAFORM. A stamping die was fabricated for experiment validation. The experimental results obtained by the coordinate grid strain analysis technology (CGSAT) agreed well with the simulation results, which demonstrated that the method presented here conduced to improving the formability of DCTAP.