Electrically Assisted Stamping and Multi-field Coupling Numerical Simulation for TA32 Straps

ZHENG Jialing; HAN Jinquan; SUN Qianyu; ZENG Gang; WAN Min; MENG Bao; LIU Zhigang

doi:10.3969/j.issn.1674-6457.2026.09.003

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (9) : 21-31. DOI: 10.3969/j.issn.1674-6457.2026.09.003

Light Alloy Forming

Electrically Assisted Stamping and Multi-field Coupling Numerical Simulation for TA32 Straps

ZHENG Jialing¹, HAN Jinquan¹, SUN Qianyu¹, ZENG Gang¹, WAN Min¹, MENG Bao^1,*, LIU Zhigang²

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Abstract

To address issues including long process cycles and poor formability in manufacturing aircraft strap components by conventional hot forming, the work aims to conduct fundamental research on electrically assisted stamping technology for determining process solution design and defect control methods. Numerical simulation via AutoFormR10 software was employed to determine a forming solution for the component without wrinkling or cracking defects. Based on the limitations of conventional hot forming processes, an electrically assisted stamping forming process was proposed. By combining Abaqus numerical simulation with thermal instability diagrams, the optimal process solution was determined, and electrically assisted stamping forming experiments were conducted to validate the process solution. By adopting the stamping forming method and reducing the height of the die flange area, a defect-free strap component could be formed. To heat the TA32 blank to a temperature range of 800 ℃ to 1 000 ℃, a DC power supply with an output current of at least 1 400 A to 1 700 A must be selected. During the electrically assisted stamping forming process, the temperature of the strap dropped significantly, with a decrease of up to 400 ℃ in the central region and a 200 ℃ drop on both sides near the rounded corners of the stiffeners. The middle and rounded corners of the strap stiffeners were identified as both high-strain and high-stress regions, with temperatures below the safe processing window, making them the most prone to instability defects. The safe temperature window for the middle of the stiffeners was determined to be 740-860 ℃, while for the rounded corners, the safe temperature window varied with strain. By heating the material to above 950 ℃ and adopting a two-step forming solution, defect-free strap components can be formed. The feasibility of this process solution is validated through electrically assisted stamping forming experiments.

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TA32 / electrically assisted stamping / forming defects / multi-field coupling

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ZHENG Jialing, HAN Jinquan, SUN Qianyu, ZENG Gang, WAN Min, MENG Bao, LIU Zhigang. Electrically Assisted Stamping and Multi-field Coupling Numerical Simulation for TA32 Straps[J]. Journal of Netshape Forming Engineering. 2026, 18(9): 21-31 https://doi.org/10.3969/j.issn.1674-6457.2026.09.003

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