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.

Evolution of Hydroforming Technologies and Its Applications — A Review

2020 ◽  
Vol 19 (04) ◽  
pp. 737-780
Author(s):  
P. Venkateshwar Reddy ◽  
B. Veerabhadra Reddy ◽  
P. Janaki Ramulu
Keyword(s):  
Tube Hydroforming ◽  
High Strength Steels ◽  
High Strength ◽  
Lightweight Materials ◽  
Hydroforming Process ◽  
Rapid Pace ◽  
Innovative Work ◽  
Ultra High Strength Steels ◽  
Different Characteristics ◽  
Forming Methods

Advanced forming technologies have been evolving at a rapid pace with the products applicability in the industrial fields of aerospace and automobile especially for the materials like aluminum and titanium alloys (light weight) and ultra-high strength steels. Innovative forming methods like hydroforming (tube and sheet) have been proposed for industries throughout the world. The ever-increasing needs of the automotive industry have made hydroforming technology an impetus one for the development and innovations. In this paper, the review on various developments towards lightweight materials for different applications is presented. The influencing process parameters considering the different characteristics of the tube and sheet hydroforming process have also been presented. General ideas and mechanical improvements in sheet and tube hydroforming are given late innovative work exercises. This review will help researchers and industrialists about the history, state of the art in hydroforming technologies of the lightweight materials.

Simulation of Hydroformed High Strength Steel Chassis Parts

2008 ◽  
Vol 575-578 ◽  
pp. 390-395
Author(s):  
Kee Joo Kim ◽  
Joo Sung Kim ◽  
Byung Ik Choi ◽  
Keun Hwan Kim ◽  
Yeon Sik Kang ◽  
...  
Keyword(s):  
High Strength Steel ◽  
Computer Aided Design ◽  
Fuel Efficiency ◽  
High Strength ◽  
Die Design ◽  
Design Stage ◽  
Cross Sectional ◽  
Global Issues ◽  
Whole Process ◽  
Aided Design

The environment and energy related problem has become one of the most important global issues in recent years. One of the most effective ways of improving the fuel efficiency of automobiles is the weight reduction. In order to obtain this goal the hydroforming technology is adapting for the high strength steel and its application is being widened. In present study, the whole process chain of chassis components (cross members) simulation and development by hydroforming technology to apply high strength steel having tensile strength of 440 MPa grade is covered. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Overall possibility of hydroformable chassis 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, preforming and hydroforming. At the die design stage, all the components of prototyping tool are designed and interference with press is investigated from the point of geometry and thinning.

An Enhanced Hybrid Springback Compensation Approach: Springback Path – Displacement Adjustment Method For Complex Shaped Products of Sheet Metal Forming

2021 ◽  
Author(s):  
Zhihui Gong ◽  
Mandeep Singh ◽  
Bohao Fang ◽  
Dongbin Wei
Keyword(s):  
Sheet Metal ◽  
Automobile Industry ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
High Strength Steels ◽  
Fem Analysis ◽  
High Strength ◽  
Design Stage ◽  
Springback Compensation ◽  
Compensation Approach

Abstract Springback compensation is critical in sheet metal forming. Advanced techniques have been adopted in the design stage of various sheet metal forming processes, e.g. stamping, some of which are for complex shaped products. However, the currently available numerical approaches are not always sufficiently accurate and reliable. To improve the accuracy of springback compensation, an enhanced hybrid springback compensation method named Springback Path – Displacement Adjustment (SP-DA) method has been developed in this study based on the well-known conventional displacement adjustment (DA) method. Its effectiveness is demonstrated using FEM analysis of low, medium and high strength steels adopted in automobile industry, in which a symmetrical model owning geometry complexity similar to an auto body panel was established. The results show this new enhanced SP-DA method is able to significantly improve the accuracy of springback compensation comparing to conventional displacement adjustment technique.

Tube and Sheet Hydroforming-Advances in Material Modeling, Tooling and Process Simulation

2005 ◽  
Vol 6-8 ◽  
pp. 1-12 ◽  
Author(s):  
Taylan Altan ◽  
H. Palaniswamy ◽  
G. Ambrogio ◽  
Yingyot Aue-u-Ian
Keyword(s):  
Production Technology ◽  
Process Simulation ◽  
Tube Hydroforming ◽  
High Strength Steels ◽  
High Strength ◽  
Material Modeling ◽  
Multiple Point ◽  
Sheet Hydroforming ◽  
Ultra High Strength Steels ◽  
Robust Process

Tube Hydroforming is a well accepted production technology in automotive industry while sheet hydroforming is used in selected cases for prototyping and low volume production. Research in advanced methods (warm sheet and tube hydroforming, double blank sheet hydroforming, combination of hydroforming and mechanical sizing, use of multi-point and elastic blank holders) is expanding the capabilities of hydroforming technologies to produce parts from Al and Mg alloys, as well as Ultra High Strength Steels. In the development of advanced hydroforming methods, experience based knowledge is not readily available. Thus, robust process simulation is required, along with adequate material modeling and identification of friction coefficients as input to process simulation. This paper gives an overview of advanced hydroforming methods, including examples of novel machine and tooling designs. The use of reliable process simulation is illustrated with examples that demonstrate the significance of material and friction date for making accurate predictions. Advanced simulation methods for warm forming and for programming multiple-point blank holder are also discussed. This review illustrates that hydroforming continues to make advances and has the potential to make many contributions to production technology in the near future.

The Influence of Temperature on Zinc Abrasion in Deep Drawing Processes

2014 ◽  
Vol 611-612 ◽  
pp. 1039-1046 ◽  
Author(s):  
Peter Sachnik ◽  
Wolfram Volk ◽  
Roland Golle ◽  
Hartmut Hoffmann
Keyword(s):  
Deep Drawing ◽  
High Strength Steels ◽  
High Strength ◽  
Heating System ◽  
Sheet Metals ◽  
Process Stability ◽  
Forming Process ◽  
Whole Process ◽  
Different Temperatures ◽  
The Impact

Due to the development of corrosion-resistant lightweight, todays automotive manufacturers typically use zinc coated sheet metals in the forming process. However, zinc abrasion in industrial presses decreases the process stability and often causes interruption of the whole process. The application of high strength steels leads to a significant increase of the temperature due to the plastic work. So far a detailed, quantitative analysis of the relation between temperature and zinc abrasion is not available. Therefore, this paper examines the impact of the temperature on abrasion behaviour in sheet metal processes. To achieve this, a progressive die was built. The deep drawing stage of this tool is connected to a cooling / heating system in order to obtain a constant temperature during the forming process. A variety of different galvanized sheet metals compared to commonly used tool materials has been tested. For each combination of materials five experiments at different temperatures were performed to determine the effect of the temperature on the zinc abrasion. Applying the method of total reflection x-ray fluorescence (TXRF) the quantity of zinc abrasion was measured. A relation between low temperatures and reduced zinc abrasion can be clearly observed. Industrial experiments revealed that temperature exerts a high influence on the zinc abrasion. The new insights into the impact of the temperature show a significant way to lower the zinc abrasion and therefore increase the process stability in deep drawing processes.

scholarly journals A Casting Mould for Rapid Tube Hydroforming Prototyping

2020 ◽  
Vol 4 (2) ◽  
pp. 29-33 ◽  
Author(s):  
Andrzej Kochański ◽  
Hanna Sadłowska
Keyword(s):  
New Technology ◽  
Tube Hydroforming ◽  
High Strength ◽  
Industrial Applications ◽  
Design Stage ◽  
Production Volume ◽  
New Approach ◽  
Low Weight ◽  
Mould Cavity ◽  
Single Part

In recent years, hydroforming has clearly expanded its range of industrial applications due to the growing interest in products which combine high strength with low weight. A current limitation of this technology was its economically justified production volume since the costs of producing tools eliminates the possibility of using hydroforming technology in prototype and single part production. The paper presents a freshly patented solution that allows for single part hydroforming. The new technology combines traditional hydroforming machines with a new approach to tool production. The new rapid die is made quickly and cheaply. The use of materials known from the production of foundry moulds causes the die to deform during hydroforming, but it is a controlled deformation. Thanks to the use of numerical modelling, the deformation of the mould cavity is predicted and taken into account at the design stage. The article presents important issues that need to be considered in the design of this innovative process.

FE Simulation and Experimental Study of Tube Hydroforming Process for AA1050 Alloy at Various Temperatures

2011 ◽  
Vol 264-265 ◽  
pp. 96-101
Author(s):  
Hassan Moslemi Naeini ◽  
Golam Hosein Liaghat ◽  
S.J. Hashemi Ghiri ◽  
S.M.H. Seyedkashi
Keyword(s):  
Elevated Temperatures ◽  
New Technologies ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Thermal Conditions ◽  
High Strength ◽  
Different Temperatures ◽  
Hydroforming Process ◽  
Production Technologies ◽  
Advanced Production

Considering the necessity of using light weight, high strength and corrosion resistant materials, automotive and aerospace industries need to use advanced production technologies. Hydroforming has been regarded as one of the new technologies in forming of aluminium and magnesium alloys. These alloys have very low formability at room temperature which will be improved at elevated temperatures. In this paper, AA1050 aluminium alloy tube is numerically and experimentally investigated at different temperatures. Thickness distribution in forming zone is studied under different thermal conditions. Numerical results have been verified by experiments and there is a good agreement.

Effect of Surface Enlargement and of Viscosity of Lubricants on Friction Behaviour of Advanced High Strength Steel Material during Deep Drawing

2014 ◽  
Vol 1018 ◽  
pp. 253-260 ◽  
Author(s):  
Markus Singer ◽  
Mathias Liewald
Keyword(s):  
Friction Coefficient ◽  
Deep Drawing ◽  
Sheet Material ◽  
High Strength Steels ◽  
High Strength ◽  
Work Piece ◽  
Advanced High Strength Steels ◽  
Steel Material ◽  
The Relationship

Increasing demands on vehicle safety and weight reduction in the automotive industry lead to an increased use of “advanced high strength steels” for car body manufacturing purposes. Mentioned material grades are having high levels of tensile strength and are often used in conventional sheet metal forming processes. One of the most significant factors on quality of stamped components as well as its manufacturing process robustness is the friction between tool and sheet material. During the deep drawing process, superposition of tensile stresses is causing enlargement of the sheet surface by a few percent. This effect can damage the zinc layer. Due to that fact, lubricant has to keep tool and work piece separated in order to prevent adhesion and abrasion. For that very reason, sufficient amount of lubricant has to be applied onto the surface texture reservoirs. Furthermore, the viscosity of lubricant is mainly influencing its ability of wetting the surface. The aim of this study is to define the relationship between friction coefficient, surface enlargement and lubrication having different viscosities. In this investigation the same amount of lubricant with viscosity of ϑ=65 mm2/s, ϑ=200 mm2/s and ϑ=400 mm2/s was applied on strips made out of DP1000 and DC04 steel. Then, the strips were stretched uniaxially, and restraining forces were measured by strip draw test considering constant surface pressure and drawing speed. In this paper, the correlation between friction coefficient, viscosity and surface enlargement for two different sheet material grades is shown.

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