Hydroforming a small scale aluminum automotive component using a layered die

The aim of this study is to investigate the possibility of manufacturing an aluminum automotive component (a small sized car door panel) using a highly reconfigurable and cheap forming process. Specifically, the sheet hydroforming process and rapid tooling technique were combined, with the objective of making the resulting process more flexible and less expensive.Sheet hydroforming experiments were carried out using a layered die created assembling 2D laser cut layers and testing three Al alloys (AA2024, AA5754, AA7475); process parameters (Closing Force and Pressure) were evaluated by means of finite element simulations, mainly focused on the curve defining the Closing Force as a function of the forming Pressure and on friction conditions, which have a significant effect on the distribution of sheet thickness in formed parts.Both numerical simulations and experimental tests highlighted that sound parts could be obtained if a hard enough sheet material together with the appropriate Closing Force and forming Pressure are used. The proposed approach, combining the hydroforming process with a rapid tooling technique, proved to be effective in rapidly manufacturing prototypes and thus in shortening the product design process.

► The sheet hydroforming process was combined with the rapid tooling technique. ► The layered die was created optimizing the number of layers through an adaptive slicing. ► No post working operation was used for improving the finishing of the layered die. ► The proper sheet material and CF-pressure profile could minimize problems related to the layered die. ► Sound parts suitable for prototyping purposes were obtained.