Embed Size (px)
Citation preview
w w w . a u t o s t e e l . o r g
Pre-Form Solutions for Hydroforming Challenges
Naji Arwashan, Ph.D.
Jay Liu, Ph.D.
Martinrea International, Inc.
w w w . a u t o s t e e l . o r g
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
w w w . a u t o s t e e l . o r g
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
w w w . a u t o s t e e l . o r g
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.
w w w . a u t o s t e e l . o r g
Problem Description
Part information:
• Part = Side rail
• Steel Grade = HSLA
• Tube Thickness = 2.25 mm
• Tube Outer Diameter = 57.15 mm
w w w . a u t o s t e e l . o r g
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
w w w . a u t o s t e e l . o r g
Forming Simulation Steps
Use LS-Dyna to simulate the three stages of manufacturing process:
1. Bending Simulation
2. Pre-form Simulation
3. Hydroform Simulation
w w w . a u t o s t e e l . o r g
Bending Simulation
Thinning= 6.1%
Thinning= 7.7%
Thinning= 7.8% Plastic-strains at end of bending are saved in “dynain” file
w w w . a u t o s t e e l . o r g
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
w w w . a u t o s t e e l . o r g
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!
w w w . a u t o s t e e l . o r g
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.
w w w . a u t o s t e e l . o r g
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
w w w . a u t o s t e e l . o r g
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.
w w w . a u t o s t e e l . o r g
North American
Light Vehicle Metallic Material Trends
Great Designs in Steel is Sponsored by:
Use your web-enabled device to download the presentations from today’s event
PRESENTATIONS WILL BE AVAILABLE MAY 3
