Production by 3D printing of modular tools for highly customizable hydroforming of light sheet metals

The present work proposes an innovative approach for producing complex shaped parts by HydroForming (HF) based on the adoption of customizable and modular polymeric dies fabricated via 3D printing. The proposed approach was tested on a benchmark axisymmetric Aluminum (Al) alloy component (AA5754-H111, initial thickness: 0.5 mm) with undercuts. The HF process was conducted at room temperature; the commercial Finite Element (FE) code Abaqus/CAE was used to define the oil pressure profile and the load applied by the blankholder to successfully fill the die cavity. In addition, the FE model allowed to study the effect of the assembly configuration of the die’s polymeric subparts in terms of shape and thickness of the component. The proposed approach provides an innovative tool that combines flexibility, adaptability, and precision for the manufacturing of complex shaped parts by HF.