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:
FEM analysis of tube pre-bending and hydroforming
Abstract FEM analysis was conducted on tube pre-bending and subsequent hydroforming for a given hydroforming tooling in order to make possible modifications and optimization for the process planning to successfully form a given tubular part. Process variables such as the friction coefficient, the tube material and the pre-bent tube radius have been analyzed within the available conditions. It was found that a lower friction coefficient can reduce thinning in the pre-bending process, that SS304 is more favorable to the forming of this part than SS409, and that a large pre-bending radius is beneficial to both pre-bending and subsequent hydroforming.
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