Numerical Simulation and Experimental Study on Liquid-Filling Forming of 2A12 Aluminum Alloy Fairing

To address the challenges of excessive local thinning, poor surface quality, and low production efficiency in traditional multi-pass deep-drawn aluminum alloy fairings, this study investigates the effects of process parameters—including liquid chamber pressure, holding force, and differentiated lubrication schemes—on the liquid-filled forming performance and wall thickness distribution of a 460 × 280 × 1.5 mm thin-walled 2A12 aluminum alloy fairing. Employing an integrated liquid-filled forming technique combining a flexible punch with a rigid die, the research combines numerical simulation with experimental validation. The study demonstrates good consistency between experimental results and numerical simulations. The optimal forming process parameters are liquid chamber pressure of 10 MPa, holding force of 1100 kN, and a lubrication scheme (friction coefficients of 0.01 for the flange and forming zones and 0.06 for the transition radius zone). Under these parameters, part wrinkling and cracking are effectively suppressed, achieving optimal wall thickness uniformity in the formed parts, with a maximum thinning rate of only 6.6%. The proposed liquid-assisted forming process and differentiated lubrication scheme provide a new technical pathway for high-precision manufacturing of thin-walled complex curved components made of 2A12 aluminum alloy. Compared to traditional multi-stage drawing processes, both forming efficiency and quality are significantly improved.