Research On Hydrofomring Samulation Of The Car’s Rear Suspension Sway ARM

In recent years, reducing vehicle weight has been more and more important forsolving the energy problem. Because of its good integrity, improved strength and stiffness,satisfied material utilization, the hollow structure of the internal high pressure forming hasbeen widely used as parts of cars. But the tube wall is easily wrinkled, excessively thinned,and even broken or clamped by the moulds during internal high pressure forming process,which is a challenge gravely to produce high quality internal high pressure forming parts.This paper takes a car’s rear suspension sway arm as the research object, carries outinternal high pressure forming research of the sway arm with software AUTOFORM, andfind out the influent factors for being thinned, wrinkled and so on.Firstly, the internal high pressure forming process of a car’s rear suspension swayarm is analyzed and the original model is modified based on the characters and requests ofmanufacture. Secondly, analysis of the influent factors of the tube wall thickness is carriedout by numerical simulation of the NC bending process. Then, those factors are sorted bytheir significance and combined by seeking their optimization through orthogonal test. Atlast, a high quality bending part is acquired. Thirdly, according to the principles of thedesign of moulds, the modular surface for pre-form is designed and the final internal highpressure forming modular surface is extracted based on the part axes and shape. Lastly,trapezoidal loading path is used after comparing current adopted loading paths. Based onthe initial value of process parameters selected, the numerical simulation is applied. Aftercomparing and studying simulate results, the trapezoidal loading path is improved and therational loading path is obtained. Ultimately, the qualified sway arm is obtained accordingto the adopted optimized process parameters, improved loading path and laser cutting.