Joining of lightweight frame structures by die-less hydroforming

Abstract

A successful approach to achieve a reduction of a car’s total weight is the implementation of lightweight strategies in the design process, e.g. using lightweight materials. An interesting alternative to conventional welding and riveting processes is joining by die-less hydroforming. This work describes an analytical model which can be used to calculate the strengths of these joints, taking into account the material parameters, joint geometry and process parameters. Additionally, validation of the model by both finite element simulations and experiments will be provided. Furthermore, investigations were carried out to implement the described methodology for a multi-joint used in a space frame structure.