Journal of the Korean Society of Manufacturing Technology Engineers (한국생산제조학회지)

The Korean Society of Manufacturing Technology Engineers (한국생산제조학회)
권호 표지
DOI QR코드

DOI QR Code

Optimization of the Hydro-Forming Process for Aluminum Bumper Beams by Using Finite Element Analysis

유한요소법을 이용한 하이드로포밍 알루미늄 범퍼빔의 성형공정 최적화

  • Son, Wonsik (School of Mechanical Engineering, Korea University of Technology and Education) ;
  • Yum, Sanghyuk (School of Mechanical and Aerospace Engineering, Seoul National University) ;
  • Lee, Jihoon (School of Mechanical Engineering, Korea University of Technology and Education) ;
  • Kim, Seungmo (School of Mechanical Engineering, Korea University of Technology and Education)
  • Received : 2017.04.18
  • Accepted : 2017.07.03
  • Published : 2017.08.15
Download PDF
⟨ Previous Next ⟩

Abstract

Hydro-forming is being employed increasingly to realize lightweight vehicular parts. The bumper beam produced by this process weighs 30% less than the conventional products with equal stiffness. However, hydro-forming involves complex parameters to obtain the target geometry and low residual stress. Parametric studies are conducted using finite element analysis to obtain optimized process conditions. Through these numerical approaches, the internal and holding pressures and feeder forward stroke along the extruded direction are optimized to achieve low residual stress and to minimize springback. The numerical results are verified by experimental observations made by employing a three-dimensional laser scanner. The numerical and experimental results are compared in terms of the springback. Both results show similar tendencies.

Keywords

References

  1. Kleiner, M., Chatti, S., Klaus, A., 2006, Metal Forming Techniques for Lightweight Construction, Journal of Materials Processing Technology, 177 2-7. https://doi.org/10.1016/j.jmatprotec.2006.04.085
  2. Choa, S. H., Jang, J. Y., 2016, Strength Analysis of Die-cast Aluminum-alloy Brake Pedals for use in Lightweight Cars, J. of the KSMTE, 25:2 138-142.
  3. Kim, S. B., Lee, K. H., Huh, H., Yoo, J. S., Lee, M.Y., 2006, Crashworthiness Evaluation of Aluminum Crash Box for an Auto-body, KSAE Fall Conference Proceedings, 1106-1111.
  4. Lee, C. J., Lee, S. B., Ko, D. C., Kim, B. M., 2012, Effect of Bead Shape in Aluminum Crash Box for Effective Impact Energy Absorption Under Low-Velocity Impact Condition, Transactions of KSME(A), 36:10 1155-1162.
  5. Han, M. S., Cho, J. O., 2013, Study on Strength Durability of Automotive Front Bumper during Driving, J. of the KSMTE, 22:4 673-679.
  6. Kang, P. H., Kim, B. J., Ryu, S. M., Son, S. M., Moon, Y. H., 2003, Analysis of Hydro-forming process for bumper stay, Proceedings of the Korean Society for Technology of Plasticity Conference 22:4 673-679.
  7. Jo, Y. J., Lee, S. K., Kim, B. M., Oh, K. H., Park, S. W., 2008, Process Development of Variable Curvature Extrusion for Automotive Aluminum Bumper, Transactions of the Korean Society of Mechanical Engineers, 233-236.
  8. Kim, Y. S., Cho, H. S., Park, C. D., Kim, Y. S., Jo, Y. J., 2000, Ebaluation of Tube Hydroformability, Transactions of Materials Processing 9:6 604-614.
  9. Lee, M. Y., Kang, C. Y., Ryu, S. J., 2004, Development of Hydroformed Automotive Parts with Heat-treatable Aluminum Extrudates, J. of the Korean Society for Heat Treatment, 17:3 165-172.