A 3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit-implicit solvent method. Considering the computational accuracy and efficiency, the optimal choices of numerical parameters and algorithms in FE modelling were determined. The formation mechanisms of cross-section distortion and springback were revealed. The effects of pre-stretching, post-stretching, friction, and the addition of internal fillers on forming quality were investigated. The results show that the stress state of profile ...
