The hydrofonning technology may bring many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower springback, improved strength and durability and design flexibility. In this study, the whole process of front sub-frame parts development by tube hydroforming using steel material having tensile strength of 440 MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydrofonnability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive engine cradle by the hydroforming process were carefully investigated. Overall possibility of hydroformable engine cradle 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 the press is examined from the point of deformed geometry and local thinning.
The hydroforming technology has been spreaded dramatically in automotive industry during the last 10 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 the tube material and forming behavior 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 automotive IP (instrument panel) beam parts development by conical tube hydroforming using a steel material having a tensile strength of 370 MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (computer aided engineering) to confirm the hydroformability in details. Effects of parameters such as geometry shape in automotive IP parts on the hydroforming process were carefully investigated. The overall feasibility of hydroformable IP parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of the tube material on every forming step such as pre-bending, preforming and hydroforming. In addition, all the components of the prototyping tool are designed and the interference with the press is examined from the point of geometry and thinning. Keywords: Hydroforming / IP-beam / conical tube / bending / thinning / Die Technologie des Innenhochdruckumformens hat sich während der letzten 10 Jahre in der Automobilindustrie stark verbreitet. Die Vorteile des Innenhochdruckumformens (geringere Dickenverminderung, effizienterer Herstellungsprozess usw.) können zum Beispiel mit der hohen Festigkeit hochfester Stähle, die normalerweise weniger verformbar sind, kombiniert werden, um Strukturkomponenten von Automobilen, die sich durch geringeres Gewicht und verbesserte Lebensdauer auszeichnen, herzustellen. Das Design und die Herstellung röhrenförmiger Komponenten erfordert das Wissen über das Rohrmaterial, das Formverhalten während des Innenhochdruckumformens und die Kontrolle des Innenhochdruckverfahrens. Diese Fragestellungen werden im Rahmen dieser Arbeit analytisch untersucht. Dabei wird die gesamte Prozesskette der Entwicklung von Armaturenbrett-Trägern mittels Innenhochdruckumformen von Stahl mit einer Zugfestigkeit von 370 MPa betrachtet. Im Stadium der Formteilgestaltung sind eine Machbarkeitsstudie und die Prozessauslegung mittels rechnerunterstützter Entwicklung notwendig, um die Umformbarkeit im Detail zu bestätgen. Der Einfluss von Parametern, wie zum Beispiel der Geometriequerschnitt der Armaturenbrett-Träger, auf das Innenhochdruckverfahren wurde sorgfältig untersucht. Die allgemeine Durchführbarkeit des Innenhochdruckumformes von Armaturenbrett-Trägern wurde mittels Analyse des Querschnitts untersucht. Weiterhin is...
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