Study On The Forming Process Of The Auxiliary Frame And The Topology Optimization Of The Mould

Energy consumption of automobile has a direct relationship with its weight, in order to save energy and production cost, and lightweight of automobile is a trend of automobile manufacturing. For manufacturing of automotive components, compared to traditional stamping, and welding, the automotive components which are made in tube hydroforming technology, have the advantages of light weight, less manufacturing procedure. The appearance of Computer Numerical Simulation Method provides a powerful tool for the design and optimization of forming procedure.For tube hydroforming procedure, maximum internal pressure of forming determines the specifications of hydraulic machine and manufacturing costs. The greater the maximum internal pressure, the higher the cost. In order to reduce forming pressure, the author uses software Dynaform to dilatancy forming of subframe, namely, when forming upper mould clamping down, pressure is given on the tube. Simulation and experimental results proved that this method can be formed under the pressure of 25 MPa, and the forming effect is pretty good.First of all, the author used CATIA to reverse out geometry model of subframe. Then, based on the geometric model, the author got specification and bending parameters, and forming die which is used for simulation.Secondly, this paper analyzed the influencing rule from bending parameters to the thinning rate of tube’s thickness. Also, the author considered the bending after rebounding forms tube billet which is available for dilatancy forming.Thirdly, according to the theoretical yield pressure 55 MPa and the determined load path interval, the author formed the subframe that meets the quality requirements.Finally, the author used optimization driven of Optistruct to design the subframe die workbench which could meet the conditions on strength, quality, smallest quality.