TUBE HYDROFORMING PROCESS DESIGNE OF TORSION BEAM TYPE REAR SUSPENSION CONSIDERING DURABILITY

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6199-6205 ◽  
Author(s):  
KYUNG-TAEK LEE ◽  
HONG-JUEN BACK ◽  
HEE-TAEK LIM ◽  
IN-SUK OH ◽  
HEON-YOUNG KIM
Keyword(s):  
Dynamic Performance ◽  
Tube Hydroforming ◽  
The Finite Element Method ◽  
Forming Process ◽  
Cross Sectional ◽  
Torsion Beam ◽  
Rear Suspension ◽  
Suspension Systems ◽  
Hydroforming Process ◽  
Beam Type

Manufacturing processes for automobile suspension components have generally considered the formability but not the durability of the suspension system, even though the latter is very important in the dynamic performance of the vehicle. Suspension systems should be designed with both formability and durability in mind. This paper describes the design of an optimal forming process to control the cross-sectional properties of the torsion beam in rear suspension systems for increased roll durability. Stamping and hydroforming simulations were performed using the finite element method to determine the optimum tube hydroforming process for producing a torsion beam with the best roll durability performance.

Numerical analysis in a beverage can utilizing tube hydroforming process

2019 ◽  
Vol 28 (6) ◽  
pp. 77-83
Author(s):  
Jorge Carlos León Anaya ◽  
José Antonio Juanico Loran ◽  
Juan Carlos Cisneros Ortega
Keyword(s):  
Mechanical Properties ◽  
Numerical Analysis ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Process ◽  
Aluminum Tube ◽  
Plastic Deformation Process ◽  
Metal Forming Process ◽  
Hydroforming Process

Numerical analysis for Tube Hydroforming (THF) was developed in this work to predict the behavior of extruded aluminum tube in a forming die for beverage can applications. THF is a metal forming process dependent of three parameters: friction between the tube and the die, internal pressure, and material properties of the tube. Strain hardening is a governing phenomenon that occurs in the plastic deformation process of metals. Hollomon’s equation offers a mathematical description of the metal behavior in the plastic zone. For a proper simulation, experimental determination of the mechanical properties of aluminum 6061-T5 were conducted and test specimens where obtained directly from the aluminum tube. Experimental data were necessary because no sufficient data of the mechanical properties of the tube were available in the literature. Numerical simulations of THF were performed, and the results were compared with analytical results for validation purposes with less than 10% of error.

Reliability Analysis of the Tube Hydroforming Process Based on Forming Limit Diagram

2005 ◽  
Vol 128 (3) ◽  
pp. 402-407 ◽  
Author(s):  
Bing Li ◽  
Don R. Metzger ◽  
Tim J. Nye
Keyword(s):  
Automotive Industry ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Probability Of Failure ◽  
Alternative Methods ◽  
Forming Limit ◽  
Forming Process ◽  
Hydroforming Process ◽  
Free Bulging

Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper. The method is based on the reliability theory and the forming limit diagram, which has been extensively used in metal forming as the criteria of formability. From the forming limit band in the forming limit diagram, the reliability of the forming process can be evaluated. A tube hydroforming process of free bulging is then introduced as an example to illustrate the approach. The results show this technique to be an innovative approach to avoid failure during tube hydroforming.

Development of an automotive rear subframe by the tube hydroforming process

2008 ◽  
Vol 222 (11) ◽  
pp. 1977-1984 ◽  
Author(s):  
K J Kim ◽  
S T Won ◽  
Y H Lee ◽  
D S Bae ◽  
C W Sung ◽  
...  
Keyword(s):  
Tube Hydroforming ◽  
High Strength Steels ◽  
High Strength ◽  
Design Stage ◽  
Tube Material ◽  
Cross Sectional ◽  
Whole Process ◽  
Steel Material ◽  
Hydroforming Process ◽  
Efficient Manufacturing

The automotive industry has shown a growing interest in tube hydroforming during recent years. The advantages of hydroforming (less thinning, a more efficient manufacturing process, etc.) can, for instance, be combined with the high strength of extra-high-strength steels, which are usually less formable, to produce structural automotive components which exhibit lower weight and improved service performance. Design and production of tubular components require knowledge about tube material and forming behaviour during hydroforming and how the hydroforming operation itself should be controlled. These issues are studied analytically in the present paper. In this study, the whole process of rear subframe parts development by tube hydroforming using steel material having a tensile strength of 440MPa is presented. At the part design stage, it requires a feasibility study and process design assisted by computer aided engineering to confirm hydroformability in detail. The effects of parameters such as internal pressure, axial feeding, and geometry shape in the automotive rear subframe by the hydroforming process were carefully investigated. The overall possibility of hydroformable rear subframe parts could be examined by cross-sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending and hydroforming. In addition, all the components of a prototyping tool are designed and interference with a press is examined from the point of geometry and thinning.

scholarly journals Hydroforming Process for an Ultrasmall Bending Radius Elbow

2018 ◽  
Vol 2018 ◽  
pp. 1-15
Author(s):  
Shangwen Ruan ◽  
Lihui Lang ◽  
Yulong Ge
Keyword(s):  
Heat Treatment ◽  
High Performance ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Welding Process ◽  
Forming Process ◽  
Sealing Performance ◽  
Lap Welding ◽  
Hydroforming Process ◽  
Bending Radius

Bent pipes are widely used in automotive, aviation, and aerospace industries for delivering fluids. Parts having small relative bending radiuses are called elbows. However, fabricating a thin-walled elbow part using the simple bending process poses many challenges. One possible way to manufacture elbows is with the stamping-welding process. The major drawbacks of this method include the decline in sealing performance and the addition in weight attributed to the lap welding process. Tube hydroforming (THF) is considered as a feasible solution to these problems. However, the forming process could be quite complex, and multistep forming is necessary. This study investigates the effects of preliminary processes on elbow forming such as bending, partition forming, and heat treatment and presents a high-performance optimized process design to achieve an ultrasmall radius elbow. The effects of multistep forming on the thickness distribution and the heat treatment on the microstructure have been evaluated. The results obtained from simulations show a reasonable agreement with those from the experiments.

Scalability of conventional tube hydroforming processes from macro to micro/meso

2017 ◽  
Vol 232 (12) ◽  
pp. 2164-2177 ◽  
Author(s):  
James Lowrie ◽  
Gracious Ngaile
Keyword(s):  
Tube Hydroforming ◽  
Small Scale ◽  
Forming Process ◽  
Element Analysis ◽  
Aspect Ratios ◽  
Small Complex ◽  
Metal Forming Process ◽  
Hydroforming Process ◽  
Increasing Demand ◽  
Complex Parts

Due to the increasing demand for small, complex parts, researchers are putting a great deal of effort into applying the metal forming process to the micro and meso world. However, the tube hydroforming process is yet to be fully realized on this small scale because of the difficulties which arise in scaling the conventional tooling to the microscale. This article discusses the difficulties that arise as a result of simply shrinking the traditional hydroforming tools to the microscale. A simple mathematical model is then proposed as a way to help designers determine the limits of the conventional punch with a tapered nose commonly used in tube hydroforming. The model is then validated by performing a finite element analysis of the punch, and the results of the model are discussed in relation to the scaling concepts posed at the beginning of this article. It is determined that as the punch shrinks down, the stresses on the punch rise significantly as a result of changing aspect ratios of the workpiece and the inability to accurately machine very small holes through the punch body. A nonconventional tube hydroforming method may therefore be required to perform micro-tube hydroforming operations, especially on harder materials.

Real-Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Gracious Ngaile ◽  
Chen Yang ◽  
Obadiah Kilonzo
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure versus feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Real Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Author(s):  
Gracious Ngaile ◽  
Obadiah Kilonzo ◽  
Chen Yang
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube Hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure vs feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Tube Buckling: An Advantage to Tube Shaping

2018 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Tube Hydroforming ◽  
Rigid Bodies ◽  
Outer Diameter ◽  
Forming Process ◽  
Tube Forming ◽  
Strength Coefficient ◽  
Tube Shape ◽  
Tube Flaring ◽  
Hydroforming Process ◽  
Proper Consideration

Tube forming is one of the most common manufacturing processes to shape the tubes. Within tube forming operations the general practice is to expand and reduce the tube end cross-section and bend the tube by means of a solid mandrel. Mostly the mandrel is rigid bodies. To reduce the friction between the tube and the tool, tube hydroforming process was evolved in which the fluid was highly pressurized to expand the tube shape to the desired shape. By reducing the friction more uniform thickness could be achieved and thus increase in formability. One of the process within tube end forming process is flaring which is the focus of this paper. In tube flaring process the conical shape rigid tool flares the end of the tube. While flaring the tube, the tube buckles if proper consideration would not have been taken. In this paper, various influencing parameters such as outer diameter to tube thickness ratio, length or the tube, the strength coefficient of the tube and conical angle of the tool were analyzed. It was noted that the most important factor affect the buckling of the tube is its strength coefficient. Considering this parameter the buckling was carried out in a set die and a tube shape was formed. The advantages of this process over similar processes were discussed.

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