Numerical Simulation And Optimization Of Tube Hydroforming

Hydroforming (THF) is a kind of non-traditional materialplastic molding method. In recent years, with its unique advantages,along with the proposal of the concept of energy saving, automobilelightweight body, it has been widely used in the automotive sector.And it continues to expand its range of applications. In this paper,the author carried out the related research with the help of themachine introduced by collaborate company. The machine(2*4000MPa) is produced by AP&T from Swedish.Firstly, the paper put the X shaped tube as the research object,studied the principles and theory. The paper researched theinfluence of linear internal pressure loading path and the gradient ofinternal pressure loading path on the forming quality of X tube withthe help of FEA and DYNAFORAM simulation software. Thepaper researched the forming process, and the relation between wallthickness thinning/thickening and the loading path of internalpressure between the, compared the similarities and differences.FINDINGS: in the early stage, slow pressure rise speed alone withenough axial feeding quantity is good for improving formingquality; internal pressure loading path and minimum wall thicknesscurve has a strong correlation, curve trend is identical. At the sametime, the paper studied the influence of friction coefficient andradius on the forming quality, draw the conclusion: small frictioncoefficient and small radius under the same conditions, can obtain the good parts. The research of X tube accumulated theory andpractice basis for the complex parts.There is no rich experience on the development suspensionrack in China. First, this article elaborated the conventional processdevelopment process of TPCA. This paper studies the suspensionrack, put forward two kinds of different process schemes, frombend to preform to the final internal high pressure forming bymeans of numerical simulation, compared the advantages anddisadvantages of the two technologies and forming quality, theoptimal plan was selected, designed the dies for the selectedprocess. Based on the actual production situation, the schemeimproves the production efficiency; ensure the final productqualification rate.