Hide menu

Simulation of Bending, Hydroforming and Mechanical Joining

In recent years, the automotive industry has shown increased interest in economical and environmental effects of cars. This has led to an increased use of lightweight parts. One attractive concept is the spaceframe, which uses extruded aluminum profiles. These are formed by a bending process and connected by castings, welds or glue. By utilizing hydroforming of the aluminum profiles a number of advantages can be gained:

  • The process ensures a better reproducibility
  • In the car assembly, hydroforming decreases the number of parts and produces parts with high tolerance

The aim of this project is to study the effects of the forming and assembling on the crashworthiness properties of the spaceframe. The study is done by using Finite Element (FE) simulations of the complete process (bending, hydroforming and crash), and mapping selected mechanical variables between the different FE models involved.

To ensure an effective and correct simulation approach, a number of topics has to be investigated:

  • Algorithms for the mapping of mechanical variables between different FE models
  • Material and failure models for anisotropic materials
  • Tools for the prediction of formability, quality assurance and product functionality

Page responsible: Bo Torstenfelt
Last updated: 2008-02-07