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

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.