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Hydro-forming Process Development of Automotive AA6061 Rear Sub-frame Side Member by Computer Aided Engineering (CAE)  

Kim, Kee-Joo (Department of Automobile Engineering, Seojeong College)
Kim, Jae-Hyun (Automotive Steel Application Research Group, POSCO)
Choi, Byung-Ik (Nano Mechanics Team, Korea Institute of Machinery & Materials)
Publication Information
Transactions of the Korean Society of Automotive Engineers / v.18, no.5, 2010 , pp. 45-49 More about this Journal
Abstract
The automotive industry has shown a growing interest in tube hydroforming during the past years. The advantages of hydroforming (less thinning, a more efficient manufacturing process, etc.) can, for instance, be combined with the high strength of extra high strength steels, which are usually less formable, to produce structural automotive components which exhibit lower weight and improved service performance. Design and production of tubular components require knowledge about tube material and forming behavior during hydroforming and how the hydroforming operation itself should be controlled. These issues are studied analytically in the present paper. In this study, the whole process of rear sub-frame parts development by tube hydroforming using AA6061 material is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Engineering) to confirm hydroformability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive rear sub-frame by hydroforming process were carefully investigated. Overall possibility of hydroformable rear sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending and hydroforming. In addition, all the components of prototyping tool are designed and interference with press is examined from the point of geometry and thinning.
Keywords
Hydroforming; Side members; AA6061; Bending; Thinning;
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Times Cited By KSCI : 1  (Citation Analysis)
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