PSI - Issue 82

Marwen Habbachi et al. / Procedia Structural Integrity 82 (2026) 84–90 Habbachi et al. / Structural Integrity Procedia 00 (2026) 000–000

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In Fig. 4c, the interaction between the tool diameter d and wall angle ψ was illustrated. As the the tool diameter increases, F z max rises accordingly, which is the result of the increase of the contact surface at the interface tool / sheet. However, the increase of the wall angle close to the critical one has contributed significantly to the drop of the forming force owing to the appearance of the material thinning.

(a)

(b)

(c) Fig. 4: Interaction e ff ects on F z max : (a) Step size / wall angle, (b) Step size / sheet thickness, (c) tool diameter / wall angle

4. Conclusion

The aim of the current research was to explore the e ff ect of interactions of step size, wall angle, and sheet thickness on the axial forming force during during the forming of frustum cone benchmark made of AA 1050A-H16 aluminum sheets using a profile trajectory. The forming force becomes a limiting factor in case of combining larger step size with thicker sheet, which necessitates careful parameter selection to prevent tool failure or excessive machine load.

References

Alaswad, A., Benyounis, K., Olabi, A.G., 2012. Tube hydroforming process: A reference guide. Materials & Design 33, 328–339.