Tube Hydroforming (THF): process optimization of an automotive component

This paper reports the results obtained during a research project funded by the Italian Government and involving several Italian Universities (PRIN INTEMA). The activities have been focused on side impact bar manufacturing by means of Tube Hydroforming process (THF). Punch movement paths and fluid pressure curve were optimized by means of FEM software (LS-DYNA) to guarantee tube sealing and material feeding during the tube deformation. The side impact bar geometry was optimized till reaching the shape guaranteeing the obtainment of safe parts with the best compromise in terms of final part geometry and thickness reduction. Different fluid pressure and punch movement paths were investigated. Once accomplished all the simulations and identified the best working solution, experimental tests were performed setting the process parameters according to the values defined during the simulation phase. Good agreement between FEM and experimental results were highlighted.