Search Results

In this paper, the application of tube Extrusion for the development of stepped tubular components is discussed. Thickness increase with respect to cold reduction of diameter is predicted with reasonable accuracy. Thickness increase, length increase and strain hardening coefficient for a given cold reduction of diameter of tube are obtained using LS-DYNA Software. True stress-plastic strain curves from the tensile test are used in the forming simulation using LS-DYNA. A special purpose machine is developed for the production of steering shaft components. Considerable reduction in weight is achieved by using stepped tubular components.

Tubular stabilizer bar for commercial vehicle is developed using advanced high strength steel material. Tubular section is proposed to replace the existing solid section. The tubular design is validated by component simulation using ANSYS Software. The tubes are then manufactured of the required size. The bend tool is designed to suit the size of the profile stabilizer bar and the prototypes are made using the tube bending machine. The strength of the tubular stabilizer is increased by using robotic induction hardening system. The tubular stabilizer bar is tested for fatigue load using Instron actuators. Higher weight reduction is achieved by replacing the existing solid stabilizer bar with the tubular stabilizer bar.

Durability of automobile stabiliser bar is assessed in the present study. Finite element analysis of the stabiliser bar is performed based on the experimental observations. Fatigue analysis is performed under cyclic loading. Fatigue analysis is performed for maximum cyclic loading conditions. Improvement is the fatigue life of stabilizer bar is analysed by shot peening. Special purpose machine is used to simulate the fatigue life of stabilizer bar. Commercial software ABAQUS is used for numerical simulation. Computational fatigue simulation software, fe-safe is used for the fatigue analysis to predict the fatigue life (number of cycles for crack initiation) and crack site location. Predicted results were compared with that of the physical test results for validation.

In the present investigation dual phase steel tubes are produced through induction heating and quench system with varied martensite and ferrite content. Thereby, spectrum of tensile properties are obtained for the given steel grade. Five most popular auto steel grade DP tubes are selected and examined for work hardening characteristics of the material. Further, Strain hardening exponent (n) is calculated for the all the grades of steel tubes used for the investigation to understand the metal forming behaviour of the DP tubular components. It is found that as the intercritical temperature increases, the strain hardening exponent decreases. Effect of cold drawing on the tensile properties of DP steel tubes are studied with various cold drawn reduction percentages. It is inferred that maximum cold reduction possible for DP tubes and strips are limited to about 10% in order to retain the dual phase steel characteristics.