Open Access

ARTICLE

Analysis and Optimization of the Electrohydraulic Forming Process of Sinusoidal Corrugation Tubes

Da Cai, Yinlong Song, Hao Jiang, Guangyao Li, Junjia Cui^*

State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha, 410082, China

* Corresponding Author: Junjia Cui. Email:

Fluid Dynamics & Materials Processing 2024, 20(4), 873-887. https://doi.org/10.32604/fdmp.2023.025833

Received 01 August 2022; Accepted 27 September 2023; Issue published 28 March 2024

Abstract

Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness. They can be produced at room temperature by the electrohydraulic forming process. In the present study, the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed. In particular, the orthogonal experimental design (OED) and central composite design (CCD) methods have been used. Through the range analysis and variance analysis of the experimental data, the influence degree of wire diameter (WD) and discharge energy (DE) on the forming quality was determined. Multiple regression analysis was performed using the response surface methodology. A prediction model for the attaching-die state coefficient was established accordingly. The following optimal arrangement of parameters was obtained (WD = 0.759 mm, DE = 2.926 kJ). The attaching-die state coefficient reached the peak value of 0.001. Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED. The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.

---

Keywords

---