针对复杂截面扭力梁内高压成形容易出现咬边和开裂的问题,以轿车V型扭力梁为例,采用数值模拟和试验方法,分析了预制坯形状对扭力梁内高压成形的影响,重点研究了压下量（Y）和侧向宽度（B）对预制坯形状和内高压成形的影响.结果表明,当Y、B分别为0.83D（D为管材直径）、0.73D和0.78D、0.78D时,得到的预制坯形状在合模时出现咬边缺陷;当Y、B分别为0.73D、0.73D和0.78D、0.68D时,得到的预制坯形状能够顺利完成合模过程,但在内高压成形时出现了开裂缺陷;当Y、B为0.78D、0.73D时,得到的预制坯能顺利成形出合格的内高压成形零件.由此可知,预制坯形状是决定复杂截面扭力梁内高压能否顺利成形的重要因素,通过控制截面的高宽尺寸和形状,可以得到合理的预制坯形状,避免内高压成形过程中缺陷的产生.%To solve the problem of wrinkling and bursting during hydroforming of a torsion beam with complicated sections,numerical simulations and experimental researches were conducted,and the effect of different combinations of pressing distance Y and lateral width B of preform shapes was studied.The results showed that the flanges occurred during dies closing when Y is 0.83 D and B is 0.73 D（D is the outer diameter of the tube）or Y is 0.78 D and B is 0.78 D,respectively.However,the bursting occurred during hydroforming when Y is 0.73 D and B is 0.73 D or Y is 0.78 D and B is 0.68 D,respectively.The hydroforming process can be successfully conducted and qualified parts can be obtained with the preform shape when Y is 0.78 D and B is 0.73D.The preform shape is the most important factor on hydroforming of a torsion beam with complicated sections,and the defects can be avoided by changing the dimensions and shapes of the preform.
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