Nowadays in Industries special automotive industry, demand of lightweight materials and new related manufacturing processes have been observed due to energy conservation, environment protection, increased vehicle safety and improved vehicle performance, and the significant pressure from global market on cost reduction. Aluminum alloys are desirable in industry due to their excellent high-strength to weight ratio, corrosion resistance, and weldability. However, at room temperature, the formability and the surface quality of the final product of these alloys are low. So in recent decade, new process has been introduced as substitution with traditional stamping or hydroforming that is named hot metal gas forming. Hot metal gas forming is a new process that is based of forming in the elevated temperature that in this process, pressure gas is used for hot metal forming. This thesis investigates new method of hot aluminum alloys forming using gas. Experimental test is designed and required equipment for forming process is made. In addition to experimental test, finite element analysis of process, in two methods, independent of temperature and temperature dependent analysis, is done by ABAQUS. Results of experimental test and finite element analysis are determination of optimum temperature for forming of special aluminum alloy, maximum formability in this process, required forming pressure, minimum thickness, thickness and temperature distribution. Results show that hot metal gas forming provides highest forming temperature for aluminum alloy blank and with increasing blank temperature up to optimum temperature of hot forming, there is reduced pressure forming and significant improvement of formability. Finite element analysis of hot metal gas forming process in ABAQUS shows that there is acceptable agreement between results of experimental test and finite element analysis based on experimental test parameters (independent of temperature finite element analysis). Therefore finite element method is used as reliable method for determination of effective parameters in the hot metal gas forming process. The comparison between results of temperature dependent and independent of temperature finite element analysis shows that based on desirable thickness distribution, available tonnage of press, and maximum formability, existence or not existence of temperature gradient and thermal conduction between blank and dies is provided and with control of temperature different between mentioned components, required purpose is gained. Keywords Hot forming, formability, gas pressure, aluminum alloy, finite element.
