Optimization of the Tube Bending Process of Taguchi's Orthogonal Matrix

This paper covers finite element simulations to evaluate tube bending process of auto chassis component i.e. trailing-arm product. The rear of the auto chassis structure is primarily composed of CTBA and trailing-arm. When a car rolls into a corner, the trailing arm reacts to roll in the same degree as the car body. During the bending process of trailing arm the tube undergoes significant deformation. Thus forming defects such as excessive thinning and flattening of the tube will be formed in the outside of the tube. In this paper, we analyzed the effect of process parameters in rotary draw bending process and searched the optimized combination of process parameters using orthogonal arrays method to minimize the forming defects. In this process we analyzed several parameters which are displacement of pressure die, boosting force, initial position of mandrel bar, dimensions of mandrel in regarding to the thinning and flattening of the tube.

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