Simulation and Analysis of Aerospace Wingtip Skin Hydroforming Process

This study investigates the hydroforming process for manufacturing an aircraft wingtip skin component using 6061 aluminum alloy sheet. It specifically examines the influence of a dual-stage forming process on the part’s thinning rate and conformance to the die. The results indicate that the wingtip skin forming sequence significantly affects material flow and the final part quality. Traditional drop hammer forming impedes material flow, leading to excessive thinning rates and poor surface quality. Adopting a dual-stage process, stretching followed by hydroforming facilitates material flow and reduces thinning in the formed regions. The initial stretching stage provides a preform shape, while subsequent adjustment of the hydroforming pressure effectively controls material flow during final forming. Insufficient hydroforming pressure hinders proper forming. When the hydroforming pressure reaches 30 MPa, the maximum thinning rate increases to 11.9%, and the lower fillet achieves excellent die conformance. This method satisfies the forming requirements, enabling the successful production of wingtip skin components with high efficiency and environmental friendly.