Hydroforming For The Pipe Beam Products Base On Numerical Simulation

The traditional manufacturing process of automobile tube beam is usually to punch and form two or more half pieces,and then weld them into a whole tube beam.The main characteristic of Tubular beam hydroforming technology can integrally form hollow parts with special cross-section whose axis is two-dimensional or three-dimensional curve.having the advantages of less process,simple mold structure,short development period,low production cost,good surface quality,high shape and dimensional accuracy,etc.Therefore,applying Hydroforming to the manufacture of automobile tube beam parts has great engineering value.Firstly,using finite element analysis methodthe of special software Dynaform,such as grid cell division,contact analysis,simulation algorithm,prediction of forming defects etc..The tube with different shapes,such as variable diameter tube,curved axis tube and tee tube,were studied for the stress and strain law,when under the condition of high pressure liquid filling forming.On this basis,taking three typical parts of automobile left / right trailing arm and rear torsion beam as research objects,Simulation analysis under different process conditions,its forming process,material thinning rate,forming defects,etc.,so as to optimize the product structure and forming process parameters.According to the simulation results,the pipe bending process,pre-forming process,hydroforming and hydraulic punching process were designed,and the parts were tested.The results show that the actual forming pressure,maximum closing pressure and material thinning are consistent with the simulation results.After the application of new technology,not only improve the quality of parts and optimize the process,but also effectively reduce the weight of the car,reduce the welding seam,reduce the operating workers,significantly improve the economic benefits of enterprises.