Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters

The hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complica...

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Main Authors: Kefan Yang, Youmin Wang, Kexun Fu
Format: Article
Language:English
Published: Wiley 2021-01-01
Series:Advances in Materials Science and Engineering
Online Access:http://dx.doi.org/10.1155/2021/9982515
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author Kefan Yang
Youmin Wang
Kexun Fu
author_facet Kefan Yang
Youmin Wang
Kexun Fu
author_sort Kefan Yang
collection DOAJ
description The hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complicated. The size of the tube blank, the design of the loading route, and the forming process parameters will have an effect on the molding quality. Closed tubular torsion automobile beam is considered as the research object to study hydraulic bulging die design and optimize forming process parameters. CATIA software is used to design torsion beam product structure and hydraulic bulging die. AMESim software is employed to design hydraulic synchronous control system for cylinders on both sides of the hydraulic bulging die. Mathematical control model is established and verified in Simulink software. DYNAFORM software is applied to conduct numerical simulation of hydraulic expansion. The supporting pressure, molding pressure, friction coefficient, and feeding quantity are taken as orthogonal experiment level factors. Maximum thinning and maximum thickening rates are taken as hydraulic pressure expansion evaluation indexes to complete the orthogonal experiments. Main molding process parameters are analyzed via orthogonal experiment results and optimized by employing the Taguchi method. Optimal hydraulic bulging parameters are obtained as follows: supporting pressure of 20 MPa, molding pressure of 150 MPa, feeding quantity of 25 mm, and friction coefficient of 0.075. Simulation analysis results indicate that the maximum thinning rate is equal to 9.013%, while the maximum thickening rate is equal to 16.523%. Finally, the design of hydraulic bulging die for torsion beam was completed, and its forming process parameters were optimized.
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spelling doaj-art-c39d79b6c32f463f91bd8cf1d27d80372025-02-03T01:24:51ZengWileyAdvances in Materials Science and Engineering1687-84341687-84422021-01-01202110.1155/2021/99825159982515Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process ParametersKefan Yang0Youmin Wang1Kexun Fu2College of Mechanical Engineering, Anhui Polytechnic University, Wuhu, Anhui 241000, ChinaCollege of Mechanical Engineering, Anhui Polytechnic University, Wuhu, Anhui 241000, ChinaCollege of Mechanical Engineering, Anhui Polytechnic University, Wuhu, Anhui 241000, ChinaThe hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complicated. The size of the tube blank, the design of the loading route, and the forming process parameters will have an effect on the molding quality. Closed tubular torsion automobile beam is considered as the research object to study hydraulic bulging die design and optimize forming process parameters. CATIA software is used to design torsion beam product structure and hydraulic bulging die. AMESim software is employed to design hydraulic synchronous control system for cylinders on both sides of the hydraulic bulging die. Mathematical control model is established and verified in Simulink software. DYNAFORM software is applied to conduct numerical simulation of hydraulic expansion. The supporting pressure, molding pressure, friction coefficient, and feeding quantity are taken as orthogonal experiment level factors. Maximum thinning and maximum thickening rates are taken as hydraulic pressure expansion evaluation indexes to complete the orthogonal experiments. Main molding process parameters are analyzed via orthogonal experiment results and optimized by employing the Taguchi method. Optimal hydraulic bulging parameters are obtained as follows: supporting pressure of 20 MPa, molding pressure of 150 MPa, feeding quantity of 25 mm, and friction coefficient of 0.075. Simulation analysis results indicate that the maximum thinning rate is equal to 9.013%, while the maximum thickening rate is equal to 16.523%. Finally, the design of hydraulic bulging die for torsion beam was completed, and its forming process parameters were optimized.http://dx.doi.org/10.1155/2021/9982515
spellingShingle Kefan Yang
Youmin Wang
Kexun Fu
Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
Advances in Materials Science and Engineering
title Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
title_full Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
title_fullStr Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
title_full_unstemmed Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
title_short Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters
title_sort design of hydraulic bulging die for automobile torsion beam and optimization of forming process parameters
url http://dx.doi.org/10.1155/2021/9982515
work_keys_str_mv AT kefanyang designofhydraulicbulgingdieforautomobiletorsionbeamandoptimizationofformingprocessparameters
AT youminwang designofhydraulicbulgingdieforautomobiletorsionbeamandoptimizationofformingprocessparameters
AT kexunfu designofhydraulicbulgingdieforautomobiletorsionbeamandoptimizationofformingprocessparameters