In this paper, the experiment and simulation results of the hydroformed automotive parts, tie bar, subframe and engine mount bracket were presented. The simulations have been performed for the entire hydroforming process and their results were used to predict and fix the forming failures. Tie bar has been produced by the tube hydroforming process. In order to test the effects of forming parameters, computer simulations of pre-bending and hydroforming operations were performed. Engine mount bracket has been produced by the tube and sheet hydroforming process. Subframe has been produced by the tube hydroforming process. Pre-bending of the tube has been performed by draw bending machine with mandrel. In the hydroforming process, the fracture occurred in the tensile region of the bent tube. The fracture was removed by moving the fracture part of the bent tube near to the die. Through hydroforming experiments and simulations, the reasonable combination of internal pressure and axial feeding was found to be necessary for the successful tube hydroforming. So, the sensitivity analysis with respect to the internal pressure and axial feeding was developed for the optimal process design of hydroforming. It was applied to the optimization of tube hydroforming process, and the tube thickness variation was minimized. The advantages of hydroformed parts include the increased strength, weight reduction, improved quality and reduced tooling costs. In hydroforming part design, the shape design to meet the strength requirement and to reduce the weight is important. Therefore, the sensitivity analysis with respect to the section shape of the hydroforming part was developed. It was applied to the shape design of the tube hydroforming part, and optimal shape with increased strength and reduced weight was achieved.
Applications of hydroforming processes to automobile parts
Anwendungen des Hydroumformens im Automobilbau
Journal of Materials Processing Technology ; 174 , 1-3 ; 42-55
2006
14 Seiten, 35 Bilder, 23 Quellen
Article (Journal)
English
Hydroumformen , Blechumformen , Rohrumformen , numerische Simulation , Motorteil , Aufhängungskomponente , Umformparameter , Biegeumformen , Ziehbiegen , Empfindlichkeitsanalyse , Innendruck , Verfahrensschema , Wanddicke , Rohrwand , Festigkeitserhöhung , Gewichtsverlust , Prozessoptimierung , Stahlrohr , Fahrzeugrahmen , Design-Optimierung
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