Study on the influence of process parameters on forming accuracy in hot incremental forming of 5A03 aluminum alloy

Aluminum alloys are widely used in various fields due to their excellent material properties, but the forming of aerospace small-batch aluminum thin-walled structures at room temperature often faces challenges such as cracking, poor accuracy, or even failure. This study combines the incremental forming process with thermal-assisted techniques to effectively improve the forming accuracy of aluminum alloy materials, thereby meeting the needs for small-batch and customized product manufacturing. In thermal incremental forming, the material is subjected to complex multi-field coupling, including force field, thermal field, and structural field, leading to highly complex deformation behavior. Therefore, by combining macroscopic and microscopic approaches, this study investigates the influence of different process parameters on the forming accuracy of 5A03 aluminum alloy pyramid-shaped components and analyzes the impact of temperature on the microstructure of 5A03 aluminum alloy, thereby identifying the optimal process parameter combination for superior forming accuracy.