The Hydrodroforming Process of an Automotive Part Aminu
Tube hydroforming (THF) is currently an active area of development in the automotive industry on account of its advantages it offers in comparison to other manufacturing processes. In this paper, four simulations were carried out having the same cross sectional area but different axial feeding and load paths to improve the process design in THF process, in order to help establish the feasibility of the THF processes for specific components and have the potential to reduce the number of forming trials required to standardize the process for production of high quality hydroforming components.In addition, the studies also focus on development of an experiment simulation procedures for the entire hydroforming process. The simulation results focus on the % reduction thickness. It has also focus on the axial feed and load paths which becomes an important and useful method for planning the process design analysis, design of forming process and also planning of the tool. Since they play an important role and also determine accordance of forming limits such as wrinkling, bursting and crushing .The geometry model is analyzed base on different axial load and load paths. The key issues include geometry modeling, materials selection, meshing, boundary conditions, load definition and contact between the tube and the dies.On the base of the simulation, an optimized process parameter combination has obtained and has been verified by the instrument panel frame hydroforming experiment. The works show that:
Finite Element Analysis of Automotive Roof Header Manufactured by Stamping Process
Roof header made of Al-6061 alloys an important component in a passenger car. Roof headers profile plays an important role in giving the befitting elegance to an automotive vehicle. The key features of the roof header are built in using the stamping operations of a sheet metal of light alloys. This work presents a methodology based on numerical simulation to predict contact pressure distribution, using Ansys a simulation software, and investigates the influences of various processing parameters in stamping process used in manufacturing of automotive roof header. From work it is observed that the total stress found 995 Mpa is more than the yield strength of the material, hence the sheet deforms into the shape of the die cavity, The elastic and plastic strain observed in the analysis is within limit i.e. (0.65 & 0.55) which is less than 1 mm/mm hence the analysis is correct.
The tube bending technology of a hydroforming process for an automotive part
Abstract This paper presents the simulation results on prebending and hydroforming processes that are used to form an automotive part, a tie bar. Two prebending simulations, by a rotary draw bending machine and a bend die, are carried out to obtain the shape change of the cross-section and the thinning of the tube and the results are compared with each other. In prebending simulation with a rotary draw bending machine, to avoid wrinkling in compressive area of the tube, a wiper die is included. A parametric study is carried out to obtain the effect of the forming parameters such as bend radius and tube thickness. The hydroforming process is simulated considering the results of the prebending simulation.