Analysis and Improvement of the Tube Hydroforming Process for Manufacturing of High Strength/Low Weight Components

本计画的目的是发展电脑模拟技术，以评估管件内高压成形的成形性，而不需花费大量的时间与成本。 该研究将： (1)确定管材液压成形的关键工艺参数，并确定它们之间的相互作用;（2） 建立一种方法来估计材料的性能，需要在高压下进行工艺模拟;（3）发展预测计算机模拟中的断裂和破裂的标准;（4）发展技术，一旦最终零件的性能被确定，就使用逆向工程技术来确定初始管的所需性能;（5）建立了一种针对特定应用场合的管材液压成形与传统制造工艺相比的经济评价方法。 这项研究项目可以产生有价值的知识，使这种液压成形工艺的全部潜力可以显着提高：（1）减少工具和工艺开发中的试验和错误，从而提高机器利用率并节省宝贵的工程工作;（2）扩大工艺的几何能力，以制造几何复杂性不断增加的零件。 除了有助于对管材液压成形工艺的基本理解外，该项目还将有助于开发基于有限元分析的工具和工艺设计指南，以实现管材液压成形的最大工艺/形状能力。

The objective of this project is to develop computer modeling techniques for evaluating formability in tube hydroforming without costly and time consuming tryouts. The study will: (1) identify the critical process parameters in tube hydroforining and determine the interactions between them; (2) establish a method for estimating material properties, needed for process simulation, under high pressure; (3) develop criteria for predicting fracture and wrinkling in computer simulations; (4) develop techniques to determine the required properties of the initial tube using reverse engineering techniques once the final part properties are specified; and (5) establish a method for economic evaluation of tube hydroforming against conventional manufacturing processes for a given application. This research project could generate valuable knowledge so that the full potential of this hydroforming process could be dramatically improved by: (1) reducing the trial and error in the tool and process development, thereby increasing the machine utilization rate and saving valuable engineering effort; and (2) expanding the geometric capabilities of the process to manufacture parts with ever increasing geometric complexity. In addition to contributing to the fundamental understanding of the tube hydroforming process, this project will contribute to the development of Finite Element Analysis based guidelines for tool and process design to achieve the maximum process/shape capability in tube hydroforming.