Hydroforming Process Design Using Finite Element Simulation for a Vehicle Instrument Panel Support Frame

Tubular hydroforming has attracted increased attention in the vehicle industry recently. This paper covers a complete hydroforming process design for an instrum ent panel frame by finite element simulation using the explicit code LS-DYNA. The manufacturing process for the instrument panel frame consists of tube pre-be nding and final hydroforming. To accomplish hydroforming process design successf ully, a thorough investigation of proper combination of process parameters such as internal hydraulic pressure and axial feeding is carried out by finite element simulation to predict the tube wall thickness and shape. An optimized process parameter combination is obtained and verified by the instrument panel frame hyd roforming experiment. The experiment shows that designed process parameters can be used in real production through FEA simulation, but tubular thinned amplitu de by FEA is less than that with the experiment.

基于Moldflow的汽车仪表板本体骨架变形分析及结构改进

以某新开发车型仪表板本体骨架为研究对象,采用成熟的注塑成型有限元分析软件Moldflow,基于ARD-RSC长玻璃纤维分析模型,对本体骨架的变形量进行分析,得出了发泡区域的变形量,结果表明,发泡区域变形量不满足发泡模要求的变形小于5 mm。根据分析结果,对比不同翘曲效应对总体变形的影响,找出了影响发泡区域变形的主要原因为产品玻璃纤维取向,经过对本体骨架结构的改进,改善了产品长玻璃纤维的分布,优化了变形,最大变形2.7 mm,满足了设计要求。

基于Moldflow的滑块零件变形优化

以某车型的内部结构件为研究对象,其中结构件使用结晶材料(含玻璃纤维),结合T0零件,使用Moldflow软件解析产品翘曲原因,使用预变形手段优化产品的翘曲变形,使产品变形量满足要求。