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DEFORM-3D software was used to simulate the forging process with liquid core. Three orthogonal tests were designed to obtain the results with solid-phase thickness, reduction amount and pressing speed as three factors. The significant factors were acquired by the range analysis which affected the values of the equivalent strain and the equivalent stress in the solid-phase region, the solid–liquid two-phase region and the liquid-phase region. We mastered the deformation law during the forging process with liquid core. Four groups of the physical models of the multilayer gradient were also established under laboratory conditions. Fifty-three sets of forging parameters data were recorded including the solid-phase thickness, the reduction amount, the pressing speed and the forming pressure in each group. We constructed the relationship equation between the forming pressure and the other three factors in Origin. The equation provided a theoretical basis for selecting the press tonnage during the forging process with liquid core. [ABSTRACT FROM AUTHOR]

Lightweight, hybrid parts are extensively used in the manufacturing of modern aerospace or automobile structures like fiber metal laminates (FMLs) to replace the monolithic metallic parts. Presently, smaller and complex-shaped FML parts are made by applying the stamp-forming techniques. However, due to limited strain of the composite fibers, such techniques are unfit for forming complex profile laminated parts. This study focuses on the use of hydro-mechanical deep drawing (HMDD) for the three layers simultaneous forming of the metallic blanks to fabricate a hemispherical structure which will then be used to make a FML part. Orthogonal test strategy is formulated to investigate the influence of variables such as cavity/pre-bulging pressures, pre-bulging height, and die-binder gap to optimize the forming conditions. FE-based experimental study is done to research the thickness distribution and spring back of the formed multilayer structure. Results show that the research is sufficient in predicting these attributes and can provide a basis to understand the fundamental phenomenon for three-layered, simultaneously formed structures. Hybrid parts fabricated by using multilayer forming can expand the application areas of FMLs. [ABSTRACT FROM AUTHOR]