Crashworthiness of aluminium tubes; Part 1: hydroforming at different corner-fill radii and end feeding levels

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Proceedings titleMATERIALS PROCESSING AND DESIGN; Modeling, Simulation and Applications; NUMIFORM '07; Proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes
Series titleAIP Conference Proceedings; no. 908
ConferenceThe 9th International Conference on Numerical Methods in Industrial Forming Processes, June 17-21, 2007, Porto, Portugal
Pages787792; # of pages: 6
AbstractThe automotive industry, with an increasing demand to reduce vehicle weight through the adoption of lightweight materials, requires a search of efficient methods that suit these materials. One attractive concept is to use hydroforming of aluminium tubes. By using FE simulations, the process can be optimized to reduce the risk for failure while maintaining energy absorption and component integrity under crash conditions. It is important to capture the level of residual ductility after forming to allow proper design for crashworthiness. This paper presents numerical and experimental studies that have been carried out for high pressure hydroforming operations to study the influence of the tube corner radius, end feeding, material thinning, and work hardening in 76.2 mm diameter, 3 mm wall thickness AA5754 aluminium alloy tube. End feeding was used to increase the formability of the tubes. The influence of the end feed displacement versus tube forming pressure schedule was studied to optimize the forming process operation to reduce thinning. Validation of the numerical simulations was performed by comparison of the predicted strain distributions and thinning, with measured quantities. The effect of element formulation (thin shell versus solid elements) was also considered in the models.
Publication date
AffiliationNational Research Council Canada; NRC Industrial Materials Institute
Peer reviewedYes
NPARC number12754964
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Record identifier3e8fe322-d1bc-4263-b382-454cef1a3e83
Record created2009-10-29
Record modified2016-05-09
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