Pre-Form Solutions for Hydroforming Challenges/media/Files/Autosteel/Great Designs in Steel... · w...

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Pre-Form Solutions for Hydroforming Challenges

Naji Arwashan, Ph.D.

Jay Liu, Ph.D.

Martinrea International, Inc.

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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

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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

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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.

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Problem Description

Part information:

• Part = Side rail

• Steel Grade = HSLA

• Tube Thickness = 2.25 mm

• Tube Outer Diameter = 57.15 mm

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Material Property

0

100

200

300

400

500

600

700

0 0.2 0.4 0.6 0.8 1 1.2

Tru

e S

tres

s (M

Pa

)

True Strain

Yield Stress = 365 MPa

R = 1.1

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Forming Simulation Steps

Use LS-Dyna to simulate the three stages of manufacturing process:

1. Bending Simulation

2. Pre-form Simulation

3. Hydroform Simulation

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Bending Simulation

Thinning= 6.1%

Thinning= 7.7%

Thinning= 7.8% Plastic-strains at end of bending are saved in “dynain” file

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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

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Hydroforming Simulation

Cross Section at closing of die

Cross Section at end of hydroforming

Expansion of the tube is

restricted to this section only!

Predicted excessive

thinning, tube splitting!

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Solution

Cross Section at closing of pre-form

die

Added beads

• The goal is to center the tube inside

the hydroforming die cavity;

• Reducing the bend radius;

• Inserting two beads in the pre-form

die.

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Implementation of Solution

Thinning is within allowable range

and split has disappeared

Cross Section before closing of the die

Cross Section at end of hydroforming

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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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North American

Light Vehicle Metallic Material Trends

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