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<p>To address cracking and rebound issues in aluminum alloy forming at room temperature, this study proposed a stamping-electrohydraulic hybrid forming (SEF) process to enhance the formability of deep concave components. A comparative analysis of the forming process and forming performance was conducted between the electrohydraulic forming (EHF) and SEF. An optimization of process parameters for SEF was completed. The results showed that the stamping stage of SEF made the shock wave energy uniformly act on more areas of the sheet and allowed enough material to flow into the forming area. These features improved the forming performance of the sheet. Compared with the EHF, the rebound of the center point for SEF was reduced by 30%. The stress and strain distribution was more uniform. The sticking film amount was increased by 2.84%. The maximum thinning rate was reduced by 35.71%. The best combination of process parameters for SEF was a discharge voltage of 3.78&#xa0;kV and a stamping depth of 16.67&#xa0;mm. Compared with the initial combination of process parameters, the sticking film amount was increased by 2.67%. The maximum thinning rate was decreased by 17.41%. These results can provide reference value for deep concave feature forming.</p>

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Forming process analysis and parameter optimization of stamping-electrohydraulic hybrid forming

  • 期刊论文

  • 发表日期：

    2026年7月28日

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  • Wenxuan Xu,
  • Chenyu Jin,
  • Mingjian Yuan,
  • Guangyao Li,
  • Junjia Cui,
  • Hao Jiang

摘要

To address cracking and rebound issues in aluminum alloy forming at room temperature, this study proposed a stamping-electrohydraulic hybrid forming (SEF) process to enhance the formability of deep concave components. A comparative analysis of the forming process and forming performance was conducted between the electrohydraulic forming (EHF) and SEF. An optimization of process parameters for SEF was completed. The results showed that the stamping stage of SEF made the shock wave energy uniformly act on more areas of the sheet and allowed enough material to flow into the forming area. These features improved the forming performance of the sheet. Compared with the EHF, the rebound of the center point for SEF was reduced by 30%. The stress and strain distribution was more uniform. The sticking film amount was increased by 2.84%. The maximum thinning rate was reduced by 35.71%. The best combination of process parameters for SEF was a discharge voltage of 3.78 kV and a stamping depth of 16.67 mm. Compared with the initial combination of process parameters, the sticking film amount was increased by 2.67%. The maximum thinning rate was decreased by 17.41%. These results can provide reference value for deep concave feature forming.