Hydroforming of sheets from aluminum and magnesium alloys at elevated temperature
- Prof. Dr.-Ing. Dr.h.c. M. Geiger
- Prof. Dr.-Ing. M. Kleiner, Universität Dortmund
As a result of industrial and basic research work hydroforming of tubes is in industrial application today for the manufacturing of highly integrated parts like car axles, exhaust tubes, fittings etc.. To use the benefits of media based forming also for large parts, the hydroforming of sheets is under intense investigation. Optimised lightweight structures shall be realised by application of modern lightweight materials like aluminium and magnesium alloys which can be optimised by even stretching and strain hardening of the sheet leading to optimal use of the material. However, forming of these materials is a challenge today due to the relatively low forming potential compared to deep drawing steel.
In the present work, hydroforming at elevated temperatures up to 300 °C for lightweight sheet metal is qualified since forming capabilities of these materials improve considerably with rising temperature. The work comprises characterisation of the influence of temperature on the material properties during and after the process as well as construction of an appropriate system technology and evaluation of the applicability of process design tools like analytical estimations and FE-simulation. By experimental results it is proven that the additional effort in system technology for warm hydroforming can technically and economically be jus-tified because extremely light parts with high strength can be manufactured.