Abstract
Recently, improvement of hybrid and electric vehicle technologies, equipped with batteries, continues to solve energy and environmental problems. Lighter weight and crash safety are required in these vehicles body. In order to meet these requirements, three-dimensional hot bending and direct quench (3DQ) technology, which enables to form hollow tubular automotive parts with a tensile strength of 1470 MPa or over, has been developed. In addition, this technology enables to produce partially quenched automotive parts. In this study, the crash characteristics of 3DQ partially quenched products were investigated as the fundamental research of the design for improving the energy absorption. Main results are as follows: (1) for partially quenched straight products in axial crash test, buckling that occurs at nonquenched portion can be controlled; (2) for the nonquenched conventional and overall-quenched curved products, buckling occurs at the bent portion at the initial stage in axial crash tests, and its energy absorption is low; (3) by optimizing partially quench conditions, buckling occurrence can be controlled; and (4) In this study, the largest energy absorption was obtained from the partially quenched curved product, which was 84.6% larger than the energy absorption of the conventional nonquenched bent product in crash test.
Highlights
Improvement of hybrid and electric vehicle technologies, equipped with batteries, continues to solve energy and environmental problems
To investigate the effects of some major factors on axial crash behavior of partially quenched curved products by 3DQ, the finite element analysis has been conducted with RADIOSS 13.0 (Altair Engineering, Inc., Troy, MI, USA) using the dynamic explicit method
The characteristics of 3DQ curved products were investigated as the fundamental research of the most suitable automotive design for improving the energy absorption capability
Summary
Improvement of hybrid and electric vehicle technologies, equipped with batteries, continues to solve energy and environmental problems. On the other hand, hydroforming technology has been developed to manufacture high-rigidity hollow components from steel tube. Generally hydroforming cannot form over 980 MPa strength tubes, and manufacturing facility required for it is large and expensive [5,6]. The technology that can manufacture more high-strength tubular components with compact and low-cost facility has been desired. This technology enables to form hollow tubular structure components of a vehicle bodies with ultrahigh tensile strength and three-dimensional shapes using steel tube. The crash characteristics of partially quenched curved products by 3DQ and the suitable design are discussed for improving the energy absorption
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