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Integrated Tube and Double Sheet Hydroforming Technology - Optimised Process for the Production of a Complex Part

机译：集成管和双片液压成形技术-用于生产复杂零件的优化工艺

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摘要

The possibility to produce lightweight components with a complex geometry enhanced, in the last decades, the industrial application of the tube hydroforming and, more recently and restricted to specific industrial fields, of the sheet hydroforming technology. The integration in one tool of a tube and a double sheet hydroforming process represents an innovative technology which further emphasises the advantages offered by hydroforming in terms of costs reduction and complexity of the manufactured part. This paper describes the design and the construction of a complex hollow part resulting from the simultaneous hydroforming of two sheets and a tubular component in one tool. The focus is set in particular on the optimisation of the joining zone between tube and sheet pair, whose geometry allows a "metallic" sealing of the gap between the sheets and the tube, i.e. without using sealing components. The contact between tube and sheet pair allows the transmission of the axial force used to support the bulging of the tube to the sheet blanks, thus increasing their draw-in in the die and, consequently, avoiding the occurrence of tearing on the part. The paper describes the optimisation of different process parameters like the shape and the dimension of the blanks, their initial positioning in the tool, the value of the axial force applied to the tubular component and the blankholder force during the preforming and the calibrating stages.
机译：在过去的几十年中，生产具有复杂几何形状的轻型部件的可能性增强了管液压成形的工业应用，并且最近又限于片状液压成形技术的特定工业领域。将管材和双层液压成形工艺集成在一个工具中代表了一项创新技术，该技术进一步强调了液压成形在降低成本和制造零件的复杂性方面的优势。本文描述了由于在一个工具中同时进行两张板材和管状部件的液压成形而形成的复杂空心零件的设计和构造。特别地，重点在于管与板对之间的接合区域的优化，其几何形状允许对板与管之间的间隙进行“金属”密封，即不使用密封部件。管和板对之间的接触允许将用于支撑管的凸出的轴向力传递到板坯，从而增加了它们在模具中的拉深，因此避免了零件上的撕裂的发生。本文描述了不同工艺参数的优化，例如毛坯的形状和尺寸，它们在工具中的初始位置，施加在管状部件上的轴向力的值以及在预成型和校准阶段的毛坯夹持力。

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