Effect of forming process variables on the crashworthiness of aluminum alloy tubes

Crash analysis and energy absorption characteristics of S-shaped longitudinal members

“…Aluminum alloys have been put forward to replace low-strength steel structural components within automobiles. The reason for using these alloys is that the design and manufacturing sectors are now trying to reduce the weight of automobiles while maintaining or improving the energy absorption [8]. Cross-sectional dimensions and material properties are the main considerations used to determine the stiffness, strength and energy absorption of box-type structures.…”

Concurrent Process-Product Design Optimization Using Coupled Nonlinear Finite-Element Simulations

“…The selected manufacturing process and the choice of process parameters can also change the material microstructure (e.g., dislocation density, texture), thereby affecting the macroscale (e.g., stress-strain) behavior of the material and the structural component Oliveira et al, 2006).…”

“…Coupled process-product (performance) simulation studies include those that have considered the manufacturing effects associated with forming and springback on crush/crash performance of tubular components (Oliveira et al, 2006;Kellicut et al, 1999;Kaufman et al, 1998;Grantab, 2006;Krusper, 2003). For example, Kellicut et al (1999) considered springback, thinning, and other parameters such as plastic strain and residual stresses in bending-crush simulations of hydroformed tubes and showed that the plastic strain has the greatest effect on the crush behavior.…”

“…Simunovic and Aramayo (2002) studied the crash response of energy absorbing components of the ultra light steel auto body vehicle models and showed that by including the history effects the energy absorption properties can change even though the difference in the overall response was relatively modest. Oliveira et al (2006) and Williams et al (2005) performed experimental and computational study of s-rail tubes and discovered that both the maximum and mean crush force values will change as a result of the manufacturing process effects. Bottcher and Frik (2003) did a similar study and showed that metal forming data is required in crash simulation of front rail panel of a vehicle model, especially in high strength dual phase steel due to its rapidly hardening characteristic.…”

Tube bending and hydroforming of aluminium alloy S-rails

“…One of the key parameters that governs the crash response of s-rails, as determined through numerical investigations by Dutton et al [3,4], Ryou et al [5] and Kaufman et al [6], is the as-formed properties, which are influenced by the fabrication route employed. Through the use of experimentally validated simulation techniques, Oliveira et al [7] confirmed that the consideration of forming history effects is of vital importance to accurately predict the s-rail crash response. In order to better understand the effect of the as-formed tube properties on the crash response of s-rails, the role of the forming processes, tube bending and hydroforming, in altering the section geometry, local strength and thickness of the tube are examined in this publication.…”