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Analysis and design of hydroforming process for automobile rear axle housing by FEM

机译:汽车后桥壳体液压成形工艺的有限元分析与设计

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摘要

An FEM program, HydroFORM-3D, for the analysis and design of tube hydroforming processes, has been developed by modifying and adding some subroutines to the previous rigid-plastic finite element program, and then applied to the hydroforming process for an automobile rear axle housing. This paper includes the theoretical background of the program development. Through a numerical simulation, an optimum process is proposed to meet the practical requirements, which shows the efficiency of the numerical simulation. Two types of hydroforming dies are analyzed by numerical simulation. The sliding-type die has the drawback of a possibility of buckling, whereas the fixed-type die causes bursting failure. The thickness distribution of the final product is affected not only by the types of die, but also by the loading paths. The potential failure site for rear axle housing predicted by the numerical simulation is consistent with the experimental results. The values of maximum axial compression force for the first and second hydroforming processes are also in good agreement with experimental data. To manufacture a sound automobile rear axle housing without failure, it is better to use the sliding-type die and it is also critical to maintain a suitable hydraulic pressure level.
机译:通过修改和添加一些子程序到以前的刚塑性有限元程序中,开发了用于分析和设计管件液压成型工艺的FEM程序HydroFORM-3D,然后将其应用于汽车后桥壳的液压成型工艺。本文包括程序开发的理论背景。通过数值模拟,提出了满足实际需要的最佳工艺,表明了数值模拟的有效性。通过数值模拟分析了两种液压成形模具。滑动式模具具有屈曲的缺点,而固定式模具导致破裂失败。最终产品的厚度分布不仅受模具类型的影响,还受加载路径的影响。数值模拟预测的后桥壳潜在失效部位与实验结果一致。第一和第二液压成形过程的最大轴向压缩力的值也与实验数据很好地吻合。为了无故障地制造出良好的汽车后桥壳体,最好使用滑动模具,并且保持适当的液压压力也很关键。

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