Structural optimization and direct reverse superplastic forming process for aluminum alloy multi cavities pallet

In this study, the structural optimization, the direct-reverse superplastic forming (SPF) process the thickness distribution and the tensile property of the industrial 5083 aluminum alloy pallet with multi-deep cavities were investigated. The tensile property was carried out at room temperature and was introduced into the finite element method (FEM) to investigate the influence of the different structures with reinforcing ribs on the mechanical property of the industrial 5083 aluminum alloy. The results showed that the structure with radial reinforcing ribs possessed good load-bearing performance. Then the split forming process was introduced and the pallet was divided into the main body and the bottom supports. The FEM was conducted to predict the direct-reverse forming process of the main body, and the results showed that the minimum thickness occurred at the bottom corner. The argon gas pressure loading path was modified and the main body of the pallet was successfully manufactured by the direct-reverse SPF process. Finally, the thickness distribution was measured and the maximum thickness difference between the FEM and experimental measurement was 0.1 mm. The tensile property of post-forming material was also investigated, and the tensile strength, yield strength and the elongation were decreased slightly.