Pre-Form Solutions for Hydroforming Challenges Naji Arwashan, Ph.D. Jay Liu, Ph.D. Martinrea International, Inc.
Martinrea Overview Corporate Engineering and manufacturing of automotive and industrial systems, modules and components Public company, trading on the Toronto Stock Exchange (TSX) under the trading symbol MRE 36 manufacturing locations in eight countries 2012: Over 12,000 employees 2012: $2.9B Canadian revenue Technologies Leading provider of engineered chassis and module systems, class A and B body-in-white, lightweight body systems and fluid systems from filler to engine Stamping & Hot-stamping Hydroforming Fluid Handling
Product Overview Engine & Transmission Engine Blocks, Transmissions, Differentials Engine/Transmission: Oil Coolers, Hoses, Tube Assemblies Engine/Transmission: Oil Fillers, Tubes, Indicators Oil Pick-Up Screen/Pipe Heater Hose Inlet/Outlet Modules Front Horizontal Rear Suspension Front Vertical Exhaust Mufflers DPS Lines EGR Tubes Air-Injection Tubes Exhaust Manifold Tubes Fuel Fuel Filler Necks Capless Refueling Systems Fuel Tank/Sender Assemblies Vapor Assemblies/Canister Hoses Fuel Line Feed/Return Assembly Systems Fuel Lines/Hoses Body & Chassis Frame Rail Assemblies Class A Surface Stampings Structural BIW Components Suspension Arms & Links Engine Cradles Center/Rear Crossmembers Suspension Twist Axles Roof Assemblies Door Intrusion Beams Bumpers Radiator Support Assemblies Trailer Hitches Dash/Plenum Assemblies Wheelhouse Assemblies Roll-Formed Rockers/Headers Appliqués Belt, Upper Reveal, Roof Ditch, D-Line & Other Exterior Decorative Moldings HVAC Air-Conditioning Lines Heater Core Inlet/Outlet Assemblies Power Steering & Brakes Brake Lines/Assemblies Power Steering Lines/Assemblies Power Steering Oil Filler, Tubes/Indicators
Hydroforming Capabilities MARTINREA HYDROFORM SOLUTIONS: Specialized in hydroforming, stamping and assembly of medium and large modules for the automotive and industrial sectors. Two Locations: 1. Brampton, Ontario. 2. Hopkinsville, Kentucky.
Problem Description Part information: Part = Side rail Steel Grade = HSLA Tube Thickness = 2.25 mm Tube Outer Diameter = 57.15 mm
True Stress (MPa) Material Property 700 600 500 400 300 Yield Stress = 365 MPa R = 1.1 200 100 0 0 0.2 0.4 0.6 0.8 1 1.2 True Strain
Forming Simulation Steps Use LS-Dyna to simulate the three stages of manufacturing process: 1. Bending Simulation 2. Pre-form Simulation 3. Hydroform Simulation
Bending Simulation Plastic-strains at end of bending are saved in dynain file Thinning= 7.8% Thinning= 6.1% Thinning= 7.7%
Preform Simulation Pre-forming consists of simple crash forming of the tube Strain history was carried over from the bending operation Plastic-strains at end of pre-forming are saved in dynain file
Hydroforming Simulation Expansion of the tube is restricted to this section only! Cross Section at closing of die Predicted excessive thinning, tube splitting! Cross Section at end of hydroforming
Solution The goal is to center the tube inside the hydroforming die cavity; Reducing the bend radius; Inserting two beads in the pre-form die. Added beads Cross Section at closing of pre-form die
Implementation of Solution Cross Section before closing of the die Cross Section at end of hydroforming Thinning is within allowable range and split has disappeared
Conclusions The position of the tube inside the hydroforming die cavity can have critical effect on the hydroforming results. Adjusting the bend radii can help better position the tube inside the die at the critical sections. Inserting beads in the preformed tube can allow better participation of the material in the forming of critical section and, therefore, less thinning and better results.
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