Research on Thinning Variation of the Copper Upper Sheet in Copper-Steel Double-Sheet Hydroforming

Sheet hydroforming has become progressively attractive in the automotive and aerospace sectors due to numerous benefits, including enhanced forming capabilities, good surface quality, and the ability to form complicated parts. A notable advantage is the simultaneous and uniform pressure distribution across the entire surface. This method makes it easier to form multi-layer sheets with complex geometries compared to conventional methods. Based on these advantages, the hydroforming of double-layer sheets for the conical part is investigated. Some features of the formed inner and outer layers, including hydraulic pressure, initial bulging pressure, wall thickness distributions are discussed in detail. Double-sheet of Cu/DC04 was selected to investigate the hydroforming process by numerical simulation method. Research results show the relationship between forming pressure and quality of 2-layer conical products. The results are meaningful in predicting shaping trends and choosing optimal technological parameters in forming sheet products using hydroforming methods.