Simulation Analysis And Experimental Research Of Internal High Pressure Forming Process In Cross Car Beam

With the continuous development of my country’s economy,automobiles have entered tens of thousands of ordinary households,and fuel-efficient automobiles have been welcomed by consumers.Reducing vehicle weight through lightweight technology is a way to save fuel.As a method to decrease the mass of cars,internal high pressure forming technology uses one integral part to replace several stamped parts to weld combined parts.Under the condition of meeting the performance of parts,it reduces the weight of auto parts by a large proportion,and is favored by many car companies.However,the parts manufactured by the internal high pressure forming technology usually have irregular external shapes,and it is not easy to study through theoretical analysis.This paper takes the instrument panel beam of a certain automobile on sale as the research objective.Through multi-objective optimization and numerical simulation combined with experimental research,it conducts in-depth exploration and research on the high-pressure forming process in the automobile instrument panel beam,and can guide Subsequent formulation of technical parameters for high pressure forming in auto parts.The detailed research content is as follows:The characteristics of stress and strain in the bulging zone are revealed through plastic forming theory;after that,in view of the geometric nonlinearity,material nonlinearity and boundary condition nonlinearity involved in the internal high pressure forming process,the finite deformation geometric nonlinearity equation and elasticity are deduced.The constitutive equation of plastic materials,and a brief introduction to the contact algorithm and friction model used in the numerical simulation analysis,and then deduces the central integral method used in the forming analysis,laying a theoretical foundation for the next analysis.A numerical simulation analysis of internal high pressure forming was carried out with a cross car beam as a case,and different processes such as one-step forming and two-step forming,the matching relationship between the internal pressure loading path and the axial feeding displacement,friction conditions,and feeding amount were studied.The influence of the plan and the main process parameters on the forming result,and a reasonable high-pressure forming process plan and main process parameters in the cross car beam were obtained.On the basis of numerical simulation and optimization,taking the cross car beam as an example,the metal deformation mechanism in the internal high pressure forming process is studied through experiments,and the experimental results are compared with the numerical simulation results,and the process plan design and process are given.Parameter setting guidelines.