FEM Analysis of Superplastic-Forming Process to Manufacture a Hemispherical Shell

Superplastic materials are characterised by extreme lightness and remarkable ductility. Instead of a punch, a gas is used to push the sheet into the die cavity, and it is precisely regulated to control the material’s strain rate. Forming a superplastic material while maintaining a high strain rate sensitivity index requires the forming gas to follow a precise pressure–time loading curve. This can be excellently predicted with the aid of the finite element method (FEM). Therefore, for the superplastic material to exhibit its best formability throughout the entire process, it is necessary to control the strain rate step by step to keep the maximum strain rate within the material’s optimal superplastic range. In this work, the results of a superplastic-forming process used to create a hemispherical shell are presented. This was carried out using both a circular blank of uniform thickness and a blank with a conical cross-section. The analysis was performed using finite element modelling. Specifically, the results obtained using 3D analysis were compared with those obtained using axisymmetric analysis for conditions of axial symmetry. Using the conical cross-section blank helped achieve a more uniform thickness distribution in the produced hemispherical shell. The success of the numerical activity was validated through results from appropriate experimental work conducted on the magnesium alloy AZ31. The results show that, by employing a blank characterised by a conical section profile, the thickness distribution appears more uniform than that of a constant-thickness blank.