The Hydro-forming is one of key technologies to realize a low-cost, light-weight and high-safety car body. The development of production engineering, by making use of a Perimeter-Frame, has been done. By experimental approach, the fact was found that Pre-Bend and Pre-Form process play a major rule in order to define product shape and manufacturing process which is suitable for Hydro-Forming. The Hydro-Forming simulation through all processes, from Bending to Hydro-Forming, has been developed and the prediction accuracy achieves inside dispersion of experimental test. Additionally, Seal Tools have been improved to be able to form even though edges of product have a non-circular section. By making use of Hydro-Forming simulation, Free Bulge method has been developed, and it enable to reduce internal pressure which required during forming process from nearly 200MPa to under 100MPa. It means that huge hydraulic press machine, not in use of conventional stamping, is not necessary. A common hydraulic press machine is enough for process. As a result, initial investment can be reduced.
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