Simulation Analysis of Torsion Beam Hydroforming Based on the Fluid-Solid Coupling Method

Hydroformed parts are widely used in industrial automotive parts because of their higher stiffness and fatigue strength and reduced weight relative to their corresponding cast and welded parts.This paper reports a hydraulicforming experimental platform for rectangular tube fittings that was constructed to conduct an experiment on the hydraulic forming of rectangular tube fittings.A finite element model was established on the basis of the fluid–solid coupling method and simulation analysis.The correctness of the simulation analysis and the feasibility of the fluid–solid coupling method for hydraulic forming simulation analysis were verified by comparing the experimental results with the simulation results.On the basis of the simulation analysis of the hydraulic process of the torsion beam using the fluid–solid coupling method,a sliding mold suitable for the hydroforming of torsion beams was designed for its structural characteristics.The effects of fluid characteristics,shaping pressure,axial feed rate,and friction coefficient on the wall thicknesses of torsions beams during formation were investigated.Fluid movement speed was related to tube deformation.Shaping pressure had a significant effect on rounded corners and straight edges.The axial feed speed was increased,and the uneven distribution of wall thicknesses was effectively improved.Although the friction coefficient had a nonsignificant effect on the wall thickness of the ladder-shaped region,it had a significant influence on a large deformation of wall thickness in the V-shaped area.In this paper,a method of fluid-solid coupling simulation analysis and sliding die is proposed to study the high pressure forming law in torsion beam.

Effects of punch size, magnetic field, and magnetorheological elastomers medium on forming T-shaped thin-walled Inconel 718 tubes

This study aims at investigating the impact of using the Magnetorheological Elastomers(MREs)medium to improve the formability of T-shaped Inconel 718 tubes during the bulging process.Besides,the influence of the punch size and the intensity of the magnetic field on the branch height and wall thickness distribution of the T-shaped Inconel 718 tubes are also explored.The results showed that the parts formed by the punch with a length of 5 mm in the pressurization zone have better forming quality.The external magnetic field can promote a high branch,and by increasing the intensity of the magnetic field,the branch height was increased and then decreased.At the same time,the magnetic field reduced the amount of material accumulation between the guiding zone and the bulging zone.Besides,it promotes the material in the guiding zone to enter the bulging zone and improve the bulging ability of the T-shaped tube.