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Tube hydroforming of steel for automotive applications. / Roger Darlington

Swansea University Author: Roger Darlington

Abstract

Tube hydroforming has the potential to produce large structural automotive components which may be utilised for weight reduction in future generation vehicles, by replacing stamped and spot-welded steel assemblies. However, limited implementation of this technology has taken place for Body-In-White...

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Published: 2003
Institution: Swansea University
Degree level: Doctoral
URI: https://cronfa.swan.ac.uk/Record/cronfa42451
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spelling 2018-08-02T16:24:29.2909995 v2 42451 2018-08-02 Tube hydroforming of steel for automotive applications. f34f7b026886400f947e7aa016319675 NULL Roger Darlington Roger Darlington true true 2018-08-02 Tube hydroforming has the potential to produce large structural automotive components which may be utilised for weight reduction in future generation vehicles, by replacing stamped and spot-welded steel assemblies. However, limited implementation of this technology has taken place for Body-In-White (B-I-W) components, due to the complexity of the process and low levels of confidence and knowledge of the technology. This is coupled with assembly issues that this technology presents for B-I-W construction. In contrast the application of this technology for sub-frame and chassis component applications has been successful, principally due to the less stringent assembly requirements and proven cost and performance related benefits. The tube hydroforming process utilises forming fluid, under high pressure, to stretch a tube blank into the shape of a die cavity. The application of the internal pressure may be accompanied by axial feeding of the tube ends to push additional tube material into the die cavity. Close control of process parameters and the die design are essential to produce successful, defect-free components. However, the behaviour and response of steel and the influence of friction under these forming conditions are unknown entities. On the basis of a critical review of literature, a research programme was initiated to engage some of the key forming issues inhibiting wide-scale implementation of steel tube hydroforming for BIW automotive applications. The principal aims of the project were to identify the fundamental influences of steel properties on the tube hydroforming process and to develop a mathematical model of the process for steel tube. The research programme entailed small-scale formability tests and large-scale experimental trials, accompanied by the development of analytical and finite element (FE) models of the tube hydroforming process for various steel grades. The analytical and FE models could be used as design aids in the development of automotive BIW hydroformed components. The research project identified significant changes in both mechanical properties and surface characteristics as a result of the Electric Resistance Welding (ERW) tube manufacturing process. This in turn had a significant impact upon the hydroforming behaviour of the steel tubes. An analytical forming limit curve (FLC) model evaluated in this thesis was deemed to provided a robust means of predicting splitting or excessive thinning of a tube hydroformed component as a result of die geometry, tube material or processing conditions. The FE models developed, which incorporated the analytical FLCs, illustrated that the tube hydroforming process could be predicted with a high level of confidence for simple components. E-Thesis Materials science. 31 12 2003 2003-12-31 COLLEGE NANME Engineering COLLEGE CODE Swansea University Doctoral 2018-08-02T16:24:29.2909995 2018-08-02T16:24:29.2909995 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised Roger Darlington NULL 1 0042451-02082018162455.pdf 10798159.pdf 2018-08-02T16:24:55.4670000 Output 21457001 application/pdf E-Thesis true 2018-08-02T16:24:55.4670000 false
title Tube hydroforming of steel for automotive applications.
spellingShingle Tube hydroforming of steel for automotive applications.
Roger Darlington
title_short Tube hydroforming of steel for automotive applications.
title_full Tube hydroforming of steel for automotive applications.
title_fullStr Tube hydroforming of steel for automotive applications.
title_full_unstemmed Tube hydroforming of steel for automotive applications.
title_sort Tube hydroforming of steel for automotive applications.
author_id_str_mv f34f7b026886400f947e7aa016319675
author_id_fullname_str_mv f34f7b026886400f947e7aa016319675_***_Roger Darlington
author Roger Darlington
author2 Roger Darlington
format E-Thesis
publishDate 2003
institution Swansea University
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
active_str 0
description Tube hydroforming has the potential to produce large structural automotive components which may be utilised for weight reduction in future generation vehicles, by replacing stamped and spot-welded steel assemblies. However, limited implementation of this technology has taken place for Body-In-White (B-I-W) components, due to the complexity of the process and low levels of confidence and knowledge of the technology. This is coupled with assembly issues that this technology presents for B-I-W construction. In contrast the application of this technology for sub-frame and chassis component applications has been successful, principally due to the less stringent assembly requirements and proven cost and performance related benefits. The tube hydroforming process utilises forming fluid, under high pressure, to stretch a tube blank into the shape of a die cavity. The application of the internal pressure may be accompanied by axial feeding of the tube ends to push additional tube material into the die cavity. Close control of process parameters and the die design are essential to produce successful, defect-free components. However, the behaviour and response of steel and the influence of friction under these forming conditions are unknown entities. On the basis of a critical review of literature, a research programme was initiated to engage some of the key forming issues inhibiting wide-scale implementation of steel tube hydroforming for BIW automotive applications. The principal aims of the project were to identify the fundamental influences of steel properties on the tube hydroforming process and to develop a mathematical model of the process for steel tube. The research programme entailed small-scale formability tests and large-scale experimental trials, accompanied by the development of analytical and finite element (FE) models of the tube hydroforming process for various steel grades. The analytical and FE models could be used as design aids in the development of automotive BIW hydroformed components. The research project identified significant changes in both mechanical properties and surface characteristics as a result of the Electric Resistance Welding (ERW) tube manufacturing process. This in turn had a significant impact upon the hydroforming behaviour of the steel tubes. An analytical forming limit curve (FLC) model evaluated in this thesis was deemed to provided a robust means of predicting splitting or excessive thinning of a tube hydroformed component as a result of die geometry, tube material or processing conditions. The FE models developed, which incorporated the analytical FLCs, illustrated that the tube hydroforming process could be predicted with a high level of confidence for simple components.
published_date 2003-12-31T03:52:59Z
_version_ 1763752625883316224
score 11.013731

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