汽车前梁多道次内高压成形

基于动力显示有限元软件eta/DYNAFORM,以汽车前梁为例,开展了回转拉伸弯曲和模具压弯多道次内高压成形工艺过程数值模拟。结合各种成形工艺下汽车前梁内高压成形极限图,分析其成形质量。在此基础上进行管坯回转拉伸预弯曲和内高压成形试验,给出了典型截面的壁厚分布,并与模拟结果进行了比较。研究结果表明,模拟结果与实验结果相一致。预弯曲成形后,管坯壁厚分布对内高压成形结果中壁厚分布具有一定的影响。多道次内高压成形模拟能够提高内高压成形模拟精度。管坯模具压弯的壁厚分布较回转拉伸弯曲的壁厚分布好,利于汽车前梁内高压成形性能提高。

A simulation study on the multi-step hydroforming process for automotive front transom

Taking an automobile front transom as a typical example,a rotary bending and a die bending multi-step numerical simulation of hydroforming were investigated,by using a dynamic explicit FEM code,eta/DYNAFORM.The forming limit diagrams of the hydroformed automobile front transom of each procedure were presented and the forming qualities were analyzed.On basis of this,experiments of tube rotary bending and hydroforming were carried out.The thickness distribution of typical section was measured and compared with the simulation result.It shows that the simulation result agrees well with the experimental result.The thickness distribution of bending influences that of hydroforming.Multi-step numerical simulation can enhance simulation precision of hydroforming.The thickness distribution of tube die bending which can help improve hydroforming quality of automobile front transom is better than the result of tube rotary bending.