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Optimization of pre-form shapes by response surface methodology for hydro-forming of 780 MPa torsion beam

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Abstract

With the increasing use of advanced high strength steel for automotive components, hydro-formed hollow components have the advantage of both high strength and high stiffness. In order to manufacture a 780 MPa torsion beam satisfied with both improved safety and lightweight, hydro-forming process of 780 MPa torsion beam was studied by experimental research and numerical simulation. Pre-form design according to central composite method was carried out to avoid forming flash and bursting during hydro-forming. Response surface model of the effect of pre-form structure on thickness distribution was developed, and significance of structural parameters on the response value was discussed. According to the genetic algorithm, an optimum pre-form shape has been obtained. An experiment was carried out on the basis of the optimum pre-form shape, and the effect of loading paths was deeply discussed on hydro-forming process. It is shown that the axial feeding within acceptable range can significantly improve the thickness distribution and forming accuracy. Finally, a well hydro-formed torsion beam is manufactured.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150090, China

    W. W. Zhang, C. Han & S. J. Yuan

  2. National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China

    C. Han & S. J. Yuan

Authors
  1. W. W. Zhang
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  2. C. Han
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  3. S. J. Yuan
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Correspondence to C. Han.

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Zhang, W.W., Han, C. & Yuan, S.J. Optimization of pre-form shapes by response surface methodology for hydro-forming of 780 MPa torsion beam. Int J Adv Manuf Technol 85, 1227–1237 (2016). https://doi.org/10.1007/s00170-015-8043-9

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  • DOI: https://doi.org/10.1007/s00170-015-8043-9

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