Aluminum alloy is widely used in many fields such as aerospace, automotive manufacturing, electronic equipment, and architectural decoration due to its advantages such as small density, high strength, and strong corrosion resistance. However, during the aluminum alloy sheet metal processing, due to its good thermal conductivity, low elastic modulus, and limited plastic deformation ability, deformation problems are easy to occur, affecting product quality and subsequent assembly. Therefore, how to effectively control the deformation of aluminum alloy sheet metal during the processing process has become a key technology.



The causes of deformation



1. Material characteristics: the elastic modulus of aluminum alloy is low, and it is easy to undergo elastic and plastic deformation under external force.

2. Processing stress concentration: in the process of stamping, bending, welding, and other processing, local stress concentration can cause uneven deformation.

3. Thermal factors: especially in the welding process, high temperature can cause local softening or grain structure change of the material, thereby causing thermal deformation.

4. Unreasonable mold and process design: such as excessive mold clearance, insufficient pressure pad force, and unreasonable process path, etc., will aggravate deformation.



Main measures for controlling deformation



# 1. Optimize material selection and pretreatment



Select the appropriate aluminum alloy grade and state (such as 5052-H32, 6061-T6) according to the product performance requirements, and carry out appropriate annealing treatment before processing to eliminate internal residual stress of the material.



# 2. Reasonable design of molds and fixtures



The design of the mold directly affects the quality of sheet metal forming. It should ensure that the mold clearance is reasonable, the pressure pad pressure is uniform, and the guiding system is stable to reduce springback and wrinkles. For complex-shaped parts, multi-pass forming or step-by-step bending process can be adopted to reduce the risk of deformation.



# 3. Optimize processing process parameters



In the process of stamping, bending, stretching, and other processing, it is necessary to control the speed, pressure, and temperature reasonably. For example, reducing the speed during stamping can help the material flow sufficiently, reducing local cracking or wrinkling; using symmetrical welding sequence and intermittent welding method in welding can effectively control thermal deformation.



# 4. Adopt advanced processing technology



The introduction of high-precision processing technologies such as CNC bending, laser cutting, plasma cutting, and laser welding can significantly improve processing accuracy, reduce human error and material damage, thereby reducing the risk of deformation.



# 5. Post-processing shaping



For minor deformation that has already occurred, it can be corrected by methods such as整形, leveling, and heat treatment. For example, using a hydraulic press for整形and flattening, or controlling the material's springback through local heating and cooling.



Summary



Controlling the deformation of aluminum alloy sheet metal is a systematic project, which requires comprehensive consideration from multiple aspects such as material selection, mold design, processing technology, and post-treatment. With the development of manufacturing technology, digital simulation (such as finite element analysis) has also been widely applied in deformation prediction and process optimization, providing a strong guarantee for the high-quality production of aluminum alloy sheet metal parts. Only by continuously optimizing the process flow and improving the technical level can deformation be effectively controlled, and the product pass rate and market competitiveness can be improved.