• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.74-81
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• 2002

Recently tube hydroforming has been widely applied to the automotive industries due to its several advantages over conventional methods. In this paper, attention is paid to comparison of an implicit and an explicit finite element method widely used for numerical simulation of a hydroforming process. For an explicit FEM, a huge amount of computational time is required because of the very small time increment to solve a quasi-static problem. Hence, when an explicit FEM is used fDr a hydroforming process, it is general to convert the real problem to a virtual problem with a different processing time and mass density by appropriate scaling factor. However it is difficult to figure out how large the scaling should be adopted enough to ignore the dynamic effects and maintain the desired accuracy. In this paper, the comparison of the results obtained from both methods focus on the accuracy of the predicted geometrical shape and the stress with various scaling factors which are applied to analyze hydroforming process of an automobile lower arm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.205-208
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• 2008

Generally, there are several types in rear suspension. The rear suspension of subframe type consisting of side member and front/rear cross member is widely used in a medium car and full car. In the small car case, the beam of tubular type without independent suspension system is used to reduce manufacturing cost. The optimized rear suspension of subframe type using hydroforming method has been developed in this study. In designing suspension, the driving stability and durability performance should be considered as an important factor. The stability is related to dynamic frequency and durability is connected with stress analysis of structure. We focus on increasing the stiffness of suspension and decreasing the maximum stress relating to durability cycle life. For making use of the merits of hydroforming which is possible to make the bead, tube expansion, and feeding in desiring position, several optimization design techniques such as shape, size, and topology optimization are proposed. This optimization scheme based on the sensitivity can provide distinguished performance improvement in using hydroforming. Through commercial software based on the finite element, the superiority of this design method is demonstrated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.262-265
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• 2003

In the present study, subframe was developed using hydroforming technology. The manufacturing process for subframe consists of tube bending, pre-forming and hydroforming. The effects of bending process for manufacturing hydroformed subframe were researched. And the variables of bending process were studied by FEM simulation. The bending method is rotary draw bending that is the most popular, cost-effective bending method for thin walled tubes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.83-86
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• 2008

In this study, friction test was proposed to obtain coefficient of friction between tube and die in guide zone of tube hydroforming and friction coefficients were evaluated at different materials, viscosity of lubricants and internal pressures. For this study, STKM11A and SUS tubes were prepared. The tube was expanded by an internal pressure against the tool wall. By pushing the tube through the tool, a friction force at the contact surface between the tube and the tool occurs From the recorded axial feeding forces, the friction coefficients between tube and die at the guide zone in tubular hydroforming can be estimated. The effects of the various internal pressures, viscosity of lubricants, tube materials, tube size and die coating on the friction forces and friction coefficients are discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.359-362
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• 2008

In this study, friction test was proposed to obtain coefficient of friction between tube and die in expansion zone of tube hydroforming and friction coefficients were evaluated at different materials, viscosity of lubricants and internal pressures. For this study, STKM11A and SUS tubes were prepared. The tube was expanded by an internal pressure against the tool wall. The tube was expanded by an internal pressure against the tool wall. By pushing the tube through the tool, a friction force at the contact surface between the tube and the tool occurs. From the measured geometries and FE analysis, the friction coefficients between tube and die at the expansion zone in tubular hydroforming can be estimated. The effects of the various internal pressures, viscosity of lubricants, tube materials and tube thickness on friction coefficients are discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.202-205
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• 2009

Tubular torsion beam of high strength steel is going about in an automotive rear axle due to the advantages of light weight and efficient rear packaging capability. High strength tubular beam can be manufactured by the hydroforming in order to ensure dimensional accuracy, while a conventional stamping has been used for steel tubular beam. Internal pressure, feeding and their combination are the key factors of controlling the process. Based on the numerical simulation and try-outs, the optimized hydroforming process conditions for the high strength tubular beam were suggested.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.44-49
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• 2001

Tube hydroforming is a relatively new technology in comparison with conventional stamping process. Thus, there is no large knowledge base to assist the product and process designers, especially from the friction point of view. This paper covers the topic f friction and lubrication with regard to tube hydroforming. It presents the fact that frictional characteristic can have an effect on the formability of specific components. It also presents the results of test about several lubricants which are used in practical press process. The presented concept describes the equipment which is required to determine the friction coefficient.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.58-61
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• 2001

An implicit finite element formulation for axisymmetric tube hydroforming is investigated. In order to describe normal anisotropy of the tube, Hill's non-quadratic yield function is employed. The frictional contact between die and tube and frictionless contact between tube and fluid are considered using the mesh-normal vector computed from finite element mesh of the tube. In order to verify the validity of the developed finite element formulation, the axisymmetric tube bulge test is simulated and simulation results are compared with experimental measurements. In the axisymmetric tube hydroforming process, an optimal hydraulic curve is pursued by performing the simulation with various internal pressures and axial forces.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.354-357
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• 2001

In the present study, front lower arm and engine cradle which are automotive chassis parts were developed using the hydroforming technology. For systematic establishment of parts development process, material properties of tube were reflected at the start of design and problems of initial design drawing were solved by forming analysis. Design and manufacturing technology of hydroforming die were established and the relationship between internal pressure and feeding stroke was studied during try-out. Durability and buckling strength of hydrofromed parts were estimated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.233-236
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• 2003

A bumper comprises a bumper face, a bumper beam for distributing the load from the impacts applied to the bumper face and reinforcing the bumper, an absorber member interposed between the bumper face and the bumper beam, and a pair of bumper stays which secure the bumper beam to the vehicle body. A conventional bumper stay structure is assembled into several stamped parts, so several processes are needed and the structure is complicated. In this study the bumper stay is applied to the tubular hydroforming which is known to have several advantages such as the reduction of the number of the process and the part weight. The thickness distribution of the tube after hydroforming and the internal energy at the event of the a compression are mainly considered to evaluate the hydro-formability and energy absorption performance.