The key parameters of hydraulic deep drawing process for 2A16 aluminum alloy sheet were optimized by the combination of the response surface method and finite element simulation (FEM) to realize the high-efficient and precision forming of the aluminum alloy thin-walled box-shaped parts used in aviation. Three process parameters of blank fillet radius

blank holder force and hydraulic pressure were selected as optimization variables

and the maximum thinning rate of aluminum alloy box-shaped part was selected as optimization evaluation index. The experimental scheme was designed by central composite design method

and the experimental data were analyzed by response surface analysis software Design Expert 12. The second-order response model of the maximum thinning rate and the process parameters of the box-shaped part was established

and the optimal process parameters combination was obtained through this model. The results show that the optimal conditions of maximum thinning rate can be met when the blank holder force is 2.8MPa

the liquid pressure is 5.3MPa and the radius of the rounded corner of the blank is 100mm. By using the optimized combination of process parameters to carry out one-step hydroforming experiment

the box-shaped parts meeting the forming quality requirements can be obtained.