Optimization of Process and Tool Development for Hydroformed Frame Rail Using FEM Simulation

摘要

The manufacturing process for a frame rail consists of tube bending, pre-expansion, pre-forming and final hydroforming a thin walled tube. Process variables such as internal pressure, end feeding and tool geometry were optimized with simulation to improve the forming safety margin of the process. The shape of cross-sections at critical locations along the tube was predicted for each forming operation.