Experiment And Simulation Of An Enginebeam Of An SUV Car Based On Internal High Pressure Forming Technology

Internal high pressure forming technology is a new type of metal forming process, has been widely used in automotive, aviation, aerospace, marine and other components in the manufacturing industry, it can solve the difficult forming problem similar to the metal tube which has bending axis and specific section, improve the traditional manufacturing process of stamping and welding, which has disadvantages of welds weak, complex process, low precision and poor fatigue strength of parts. Within high pressure forming process to produce automotive engine beam, can make the strength of high stiffness, light quality, no weld, material uniform distribution, and less processing operations, forming precision, improve production technology and production efficiency. It has very good application prospect.This article adopts the method of experiment and simulation analysis, the internal high pressure forming process of an engine beam of a SUV car was studied. Firstly, in order to test the internal high pressure forming process of aluminum alloy tubes, a simple tube bulging experiment platform has been built, then the process are simulated by using the method of finite element simulation, experimental and simulation results were compare and the correctness of finite element simulation analysis was verified in the accuracy of the high pressure bulging process. Based on this, in view of the internal high pressure forming process of the engine beam, the project of bending process, preform process, high pressure bulging process were studied gradually with the simulation analysis method. The mould structure were designed, the main parameters of the process were formulated, the loading paths were planned, and the preventive measures for various defect types were described. Finally, within the evaluation method of forming limit diagram, determined the rationality of the design of the forming processes.Results showed that, the beam forming suitable for using CNC tube bender for 8 times bending in advance, then rational design the preform die for preform process, finally complete the internal high pressure forming process of the beam by the multiple linear loading paths.This article not only has good engineering application prospects, theoretical significance and experiment, also plays an important role in producing the engine beam by high pressure forming process, and broadens the way of internal high pressure forming technology widely used in automobile body parts.