Abstract
The hydroforming technology may bring many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower springback, improved strength and durability and design flexibility. In this study, the whole process of front sub-frame parts development by tube hydroforming using steel material having tensile strength of 440 MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive engine cradle by the hydroforming process were carefully investigated. Overall possibility of hydroformable engine cradle parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydroforming. At the die design stage, all the components of prototyping tool are designed and interference with the press is examined from the point of deformed geometry and local thinning.
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