Publication

Abstract : This study investigates the shell hydroforming of 1.2 mm-thick AA5052 aluminum alloy sheets to produce hemispherical domes which possess inherent spatial symmetry about their central axis. Shell hydroforming is widely used in fabricating lightweight, high-strength components for aerospace, automotive, and energy applications. The forming process was driven by a spatially symmetrical internal pressure distribution applied uniformly across the blank to maintain balanced deformation and minimize geometrical distortion. Experimental trials aimed at achieving a dome depth of 50 mm revealed wrinkle formation at the blank periphery caused by circumferential compressive stresses symmetrical in nature with respect to the dome’s central axis. To better understand the forming behavior, a validated 3D finite element (FE) model was developed, capturing key phenomena such as material flow, strain rate evolution, hydrostatic stress distribution, and wrinkle development under symmetric boundary conditions. The effects of the internal pressure (IP), blank holding force (BHF), coefficient of friction (CoF), and flange radius (FR) were systematically studied. A strain rate of 0.1 s−1 in the final stage improved material flow, while a symmetric tensile hydrostatic stress of 160 MPa facilitated dome expansion. Although tensile stresses can induce void growth, the elevated strain rate helped suppress it. An optimized parameter set of IP = 5.43 MPa, BHF = 140 kN, CoF = 0.04, and FR = 5.42 mm led to successful formation of the 50 mm dome with 19.38% thinning at the apex. Internal pressure was identified as the most critical factor influencing symmetric formability. A process window was established to predict symmetric failure modes such as wrinkling and bursting.