scholarly journals Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Kefan Yang ◽  
Youmin Wang ◽  
Kexun Fu
Keyword(s):  
Friction Coefficient ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Die Design ◽  
Molding Pressure ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Torsion Beam ◽  
Supporting Pressure ◽  
Hydraulic Bulging

The hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complicated. The size of the tube blank, the design of the loading route, and the forming process parameters will have an effect on the molding quality. Closed tubular torsion automobile beam is considered as the research object to study hydraulic bulging die design and optimize forming process parameters. CATIA software is used to design torsion beam product structure and hydraulic bulging die. AMESim software is employed to design hydraulic synchronous control system for cylinders on both sides of the hydraulic bulging die. Mathematical control model is established and verified in Simulink software. DYNAFORM software is applied to conduct numerical simulation of hydraulic expansion. The supporting pressure, molding pressure, friction coefficient, and feeding quantity are taken as orthogonal experiment level factors. Maximum thinning and maximum thickening rates are taken as hydraulic pressure expansion evaluation indexes to complete the orthogonal experiments. Main molding process parameters are analyzed via orthogonal experiment results and optimized by employing the Taguchi method. Optimal hydraulic bulging parameters are obtained as follows: supporting pressure of 20 MPa, molding pressure of 150 MPa, feeding quantity of 25 mm, and friction coefficient of 0.075. Simulation analysis results indicate that the maximum thinning rate is equal to 9.013%, while the maximum thickening rate is equal to 16.523%. Finally, the design of hydraulic bulging die for torsion beam was completed, and its forming process parameters were optimized.

Study on the Forming Process Parameters of Automobile Front Panel Reinforcing Plate Using Orthogonal Experiment Method by Numerical Simulation Technology

2014 ◽  
Vol 543-547 ◽  
pp. 337-343
Author(s):  
Peng Chong Guan ◽  
Jia Wei Fan ◽  
Li Hui Wang ◽  
Hai Peng Li ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Die Design ◽  
Front Panel ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Experiment Method ◽  
Orthogonal Experiment Method

A methodology to design optimal forming process and relative parameters of the automobile front panel reinforcing plate, using the numerical simulation technology of forming sheet metal, is investigated. The digital model of the complex automobile part is established by computer aided design software. Dynaform software is used to simulate its forming process to acquire the feasible process parameters affecting its formability. Forming limit diagram and thickness distribution diagram are used to evaluate the simulation results of different process schemes. The orthogonal experiment method is adopted to design and simulate the process parameters to find out the optimum values for die design. The reasonable process design and optimum values of fillet radius of female die, friction coefficient and blank-holder force are obtained, which can reduce the tendencies of wrinkling, crackling and thickness reduction, and achieve sufficient plastic deformation of blank.

Sheet Metals Forming Die Design Using Finite Element Analysis and the Taguchi Method

2014 ◽  
Vol 621 ◽  
pp. 195-201
Author(s):  
Surangsee Dechjarern ◽  
Maitri Kamonrattanapisut
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Coefficient ◽  
Taguchi Method ◽  
Finite Element Model ◽  
Sheet Metal ◽  
Element Model ◽  
Die Design ◽  
Forming Process ◽  
Element Analysis

Sheet metal deep-draw die is primarily constructed with draw bead, which is then modified based on trial and error to obtain a successful forming without splitting. This work aims at a robust design of forming die using numerical analysis and the Taguchi method. A three dimensional elastoplastic finite element model of a sheet metal forming process of SPCEN steel has been successfully developed using the material flow stress obtained from the modified Erichsen cup test. The model was validated with the actual forming experiment and the results agreed well. The influence of draw bead parameters on splitting and thinning distributions were examined using the Taguchi method. Four parameters, namely the friction coefficient, draw bead height, radius and shoulder radius were investigated. The Taguchi main effect analysis and ANOVA results show that the height and shoulder radius of the draw bead are the most important factor influencing the thinning distribution. Applying the Taguchi method and using the minimum thinning percentage as the design criteria, the optimum die design was identified as height, radius, shoulder radius and the friction coefficient of 4, 8, 8 mm and 0.125 respectively. The verified finite element model using the optimum die design was conducted. The predicted Taguchi response was within 5.9% from finite element analysis prediction. The improvement in the reduction of thinning percentage was 22.35%.

scholarly journals Optimization of Process Parameters of Stamping Forming of the Automotive Lower Floor Board

2014 ◽  
Vol 2014 ◽  
pp. 1-9 ◽  
Author(s):  
Guoying Ma ◽  
Binbing Huang
Keyword(s):  
Process Parameters ◽  
Production Efficiency ◽  
Simulation Analysis ◽  
Orthogonal Experiment ◽  
Production Costs ◽  
Main Process ◽  
Forming Process ◽  
Optimization Of Process Parameters ◽  
Automobile Panel ◽  
Thinning Rate

There are many process parameters which have great effect on the forming quality of parts during automobile panel stamping forming process. This paper took automotive lower floor board as the research object; the forming process was analyzed by finite element simulation using Dynaform. The influences of four main process parameters including BHF (blank holder force), die corner radius, friction coefficient, and die clearance on the maximum thinning rate and the maximum thickening rate were researched based on orthogonal experiment. The results show that the influences of each value of various factors on the target are not identical. On this basis, the optimization of the four parameters was carried out, and the high quality product was obtained and the maximum thinning rate and maximum thickening rate were effectively controlled. The results also show that the simulation analysis provides the basis for the optimization of the forming process parameters, and it can greatly shorten the die manufacturing cycles, reduce the production costs, and improve the production efficiency.

COF Measurement of Tubes by Hydraulic Bulging with Radial Crushing

2011 ◽  
Vol 189-193 ◽  
pp. 2597-2600
Author(s):  
Lian Fa Yang ◽  
Cong Qiang Wu ◽  
Feng Jun Chen
Keyword(s):  
Internal Pressure ◽  
Fe Simulation ◽  
Tube Hydroforming ◽  
Measuring Method ◽  
Relative Displacement ◽  
Hydraulic Pressure ◽  
Radial Compression ◽  
Forming Process ◽  
The Coefficient Of Friction ◽  
Hydraulic Bulging

A new method of determining the coefficient of friction (COF) in expansion zone of tube hydroforming (THF) is proposed. The measuring method features that a round tube is hydro-formed into a square one by a radial compression accompanying a constant internal hydraulic pressure p, and the difference ΔL of the two diagonal lengths of the square section of deformed tube is taken as measuring index for COF. The relationships between the ΔL and the p, COF, relative displacement S/S0 of moving punches are established by the finite element (FE) simulation of the forming process. The COF can be determined by matching the indexes ΔL from experiments and simulation. The FE simulation results show that the measuring index ΔL is in exponent proportion to COF and the internal pressure p, it is extremely sensitive to the friction force or COF and conveniently measured and especially under a higher internal pressure.

Study on the Forming Process Parameters of Sleeper Fixed Reinforcing Plate Using Orthogonal Experiment Method by Numerical Simulation Technology

2012 ◽  
Vol 268-270 ◽  
pp. 458-463
Author(s):  
Hai Peng Li ◽  
Xue Xia Wang ◽  
Li Hui Wang ◽  
Jia Wei Fan ◽  
Ju Yuan Zhao
Keyword(s):  
Process Parameters ◽  
Orthogonal Experiment ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Design Parameters ◽  
Forming Limit ◽  
Forming Process ◽  
Distribution Diagram ◽  
Experiment Method ◽  
Orthogonal Experiment Method

This paper presents a methodology to design optimal forming process parameters of the sleeper fixed reinforcing plate based on the use of computer aided engineering (CAE) technology. The methodology uses Unigraphics software to establish the numerical model and DYNAFORM software to simulate its sheet forming process to determine the feasible process parameters affecting its manufacturability, including whether the mould requires the binder, binder force, friction coefficient, and die fillet radius. The forming limit diagram and the thickness distribution diagram are selected to appraise and analyze the forming results. The orthogonal experiment method is adopted to simulate the design parameters to find out the optimum values for mould design.

Process Parameter Optimization for Better Hydro-Forming Performance of a Trailing Arm Tube

2013 ◽  
Vol 465-466 ◽  
pp. 704-708
Author(s):  
Shen Yung Lin ◽  
Hong Yi Liao
Keyword(s):  
Process Parameters ◽  
Wall Thickness ◽  
Tube Wall ◽  
Thickness Distribution ◽  
Equivalent Stress ◽  
Process Parameter ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Tube Wall Thickness ◽  
Forming Characteristics

This work presents the tube forming characteristics of a trailing arm which the whole forming processes are arranged through pre-bending twice and hydro-forming once. This work utilizes the finite element method to simulate the hydro-forming process of the trailing arm by changing the process parameters, such as velocity of left and right punches and internal hydraulic pressure, etc. The effects of process parameters on the distribution states of the tube wall-thickness, distribution of equivalent stresses and strains, and formability of the forming arm are thus investigated. Taguchi method, orthogonal array and factor response are then applied together to determine the optimal process parameter combinations corresponding to two single-quality objects, minimum tube wall-thickness and maximum equivalent stress, with nominal-the-best and smaller-the-better, respectively. It shows that the velocity of the right punch for the billet material axial feeding supplement should be larger than that of the left punch preventing the uneven bursting of the tube-wall on right-end. The analysis of variance also shows that left punch velocity is a major contribution parameter for tube wall-thickness while that primarily affects the equivalent stress is the internal pressure.

The Numerical Simulation of Air Bulge Forming of Profiled Can

2010 ◽  
Vol 97-101 ◽  
pp. 2774-2778
Author(s):  
Jie Jin ◽  
Xin He
Keyword(s):  
Numerical Simulation ◽  
Parameter Estimation ◽  
Friction Coefficient ◽  
Process Parameters ◽  
Wall Thickness ◽  
Process Parameter ◽  
The Other ◽  
Technological Parameters ◽  
Forming Process ◽  
Inner Pressure

Air bulge forming is a forming process where an inner pressure deforms the material to the shape of a die cavity. The main concerns about such a process of profiled cans are to avoid wall thickness reduction, wrinkling and bursting. The success of this process strongly depends on the choice of process parameters, i.e. the properties of material, thickness and inner pressure. By transforming the problem into a deformation controlled rather than a force controlled process, the results from the process parameter estimation become more reliable but on the other hand less intuitive. In this context, the influence of materials, friction coefficient, transitional fillet radius, thickness and bulging load are studied and some suited technological parameters and forming rules are obtained. The most important point is that the simulation and results of experiments are probably consistent.

The Development of Database of Rubber Bladder Forming Process Parameters Based on Visual Basic

2014 ◽  
Vol 971-973 ◽  
pp. 1958-1961
Author(s):  
Ling Yun Zhang ◽  
Peng Zhang ◽  
Li Qi Zhou
Keyword(s):  
Process Parameters ◽  
Visual Basic ◽  
Die Design ◽  
Sql Server ◽  
Forming Process ◽  
Relation Database ◽  
Attribute Data ◽  
Metal Rubber ◽  
Database Technology ◽  
Forming Characteristics

Forming process parameters are used for providing reference to forming process and die design, which are achieved from uniaxial tension and simulation tests. The forming characteristics in the as-quenching conditions are different from the annealing and T3 status. Database is involved in any kind of hydraulic stretch forming materials parameters used. Its application scope is broad. The graphics data and attribute data are managed using SQL server relation-database technology, management information system is developed by using Visual Basic. The database is convenient to query, retrieve for relevant personnel .Then it provides reliable basis for sheet metal rubber bladder forming more accurately.

Study on preparation process parameters and tribological properties of porous PI materials

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Yanhong Yan ◽  
Chengwen Yang ◽  
Yanfei Zhou ◽  
Wenbin Dong ◽  
Pengjuan Yan ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Process Parameters ◽  
Tribological Properties ◽  
Orthogonal Experiment ◽  
Optimal Combination ◽  
Tribological Test ◽  
Content Type ◽  
Low Load ◽  
Bearing Materials ◽  
Size And Morphology

Purpose Previously, the effect of pore-forming agents on the properties of pore size and morphology was studied. In this paper, we determine the optimal combination of parameters by tensile strength and perform tribological tests with optimal combination of parameters. Design/methodology/approach In this paper, porous polyimide (PI) materials were fabricated using vacuum hot molding technology. The orthogonal experiment was designed to test the mechanical properties of porous PI materials with the process parameters and the content of pore-forming agent as the changing factors. The porous PI oil-bearing materials were obtained by vacuum immersion, and tribological test were carried out. Findings The results showed that porous PI oil-bearing materials are suitable for low-speed and low-load conditions. The actual value of the friction coefficient basically match with the theoretical value of the regression analysis, and the errors of the friction coefficient are within 10% and 3%, respectively, which proves that the method used in the study is feasible for the friction coefficient prediction. Originality/value In this paper, we have produced a new porous oil-bearing material with good tribological properties. This study can effectively predict the friction coefficient of PI porous material.

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