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A new programming logic control method is proposed to predict the pressure during the superplastic forming process with improved forming characteristics of AA 5083 alloy sheets. The method has produced a better uniformity thickness profile in a complex, multidimensional profile in comparison with existing methods. To optimize pressure during the forming process, it is possible to maintain an optimum strain rate. Accurate control of the magnitude and duration of forming pressure and, as a result, the achievement of uniform thickness distribution in the taper angle, die corner, entry regions, and micro-forming of the multidimensional dome has been proved in this paper. Profiles formed without significant wrinkles and necking have been obtained via the fine adjustment of the applied pressure. The experimentally obtained results, using a multidimensional dome profile, are compared with the finite element method (FEM) simulated results and both are found to be in good agreement. The influence of key factors such as strain rate sensitivity index and friction coefficient on the optimum pressure-time cycle and also on the thickness distribution of the profile have been investigated and optimized. Furthermore, the microstructure was examined in parent metal and superplastically formed components.

An Experimental Investigation and Numerical Simulation in SPF of AA 5083 Alloy using Programming Logic Control Approach