Adjustable Tube Hydroforming Process Design And Mold Optimization

With the rapid development of China's automobile industry, the body andthe fine details design of the structure gradually spread over a variety of models.More stringent requirements from environmental protection and energyemissions and conservation, the pursuit of high efficiency and lightweight hasbecome an important factor in its ability to remain competitive in the automotiveengineering industry. In order to meet rising customer demands, not only inmaterial terms of performance is necessary to improve, and structural designmust combine with modern processing technology showing a new generation ofmanufacturing level. Hydroforming technology is a modern manufacturingtechnology to changing the auto industry structural design concepts, itsadvantages have been referred by a lot of thesis in detail. With hydroformingtechnology in the automotive industry, aerospace industry and other areas rapidspread, process standards did not work out due to the development of arelatively short history due to many deficiencies gradually reflected.In this context, this project to carry out the products as the simplest andmost typical adjustable tube hydroforming deformation law study for revealingthe impact of the hydroforming process parameters on product quality. Freebulging process simulation analysis to inspect the basic forming process and itsthickness distribution law affected from friction conditions on final productquality. Axial displacement control is working for the feeding. Different feedingpressure was analyzed to search the expected pressure range. Results of bothcases of friction and no-friction were compared, and both have the same trendthat as the feeding pressure increasing the minimum thickness.Contact and friction were most difficult problem in hydroforming, thatwould be solved with a optimized model. Inspecting into the history ofdevelopment of T-shape's model, the concept of separated model was regardedas a landmark that made the balance punch born. For vanishing effect of thefriction, the contact area decreased in this model that guide zone and transition zone were separated further as movable partitions. Beside the forming zonethere was no area where sliding friction happened, that simplified the situationof contact. It showed that optimization of the model improved the distribution ofSTH.