The influences of the plastic melt pressure and its distribution from the gate to the end of the mold, and of the friction coefficient between the sheet flange and the mold on forming process of the aluminum sheet have been investigated by Finite Element Method. It was shown that further deformation is mainly concentrated on metal sheet around the root corner of the mold, and that two highly strained zones with the severest thickness reduction are formed when the plastic melt pressure increased from 30 MPa to 50 MPa. The deformation of the sheet flange decreased and biaxial tension in plane of the sheet in the mold increased with increase of the friction coefficient. The non-uniform distribution of the plastic melt pressure had negligible influence on forming process of the sheet.
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