Dimensional change and springback of spherical shell in cryogenic forming

Cryogenic forming has been developed to manufacture thin-walled curved aluminum alloy components, whose final dimensions are affected by cryogenic shrinkage and springback. Therefore, dimensional changes of spherical shell in cryogenic forming were studied theoretically and experimentally. The cryogenic forming process was discussed to elucidate the factors affecting the dimensional change. The stress distribution was analyzed to qualitatively reveal the springback behavior. Cryogenic dimensional measurement devices were built to quantitatively evaluate the dimensional changes in the forming processes of punch cooling, springback, and specimen restoration to room temperature. The temperature dependencies of the elastic modulus and expansion coefficient were modeled to quantitatively calculate the effect of thermal expansion and contraction on the dimensions of specimen and punch. The theoretical analysis results indicate that depth reduction and opening expansion are produced by cryogenic springback, determined by the radial stress, hoop stress, and bending moment in different deformation regions. The cryogenic springback in the biaxial tensile stress zone was reduced by 37.8 % owing to the increasing radial deformation and decreasing bending deformation. In contrast, cryogenic springback in the tensile-compressive stress zone increased by 30.8 %. The punch cooling shrinkage and specimen warming expansion in depth direction can reduce for the dimensional deviation caused by springback but cause the opposite effect in hoop direction. Expansion and shrinkage were effectively predicted using the proposed model, with an error of less than 16 %. The deformation region of the biaxial tensile stress can be enlarged by the significantly improved hardening ability at cryogenic temperature, which benefits enhancing deformation uniformity and further reduces springback. Therefore, cryogenic forming offers considerable potential for the precision manufacturing of aluminum alloy deep-cavity thin-walled components.