Development of Hydroformed High Strength Steel Chassis Part 2005-01-0091

It is gaining more and more weights, the efforts in cost down and lightweighting of new part development in the automotive industry. In order to obtain this goal the hydroforming technology is adapting high strength steel and its application is being widened. In this study, whole process chain of chassis part development by hydroforming technology to apply high strength steel of TS 440MPa grade is covered. At the part design stage, it requires feasibility study and process design aided by CAE to confirm hydroformabilty in details. Overall possibility of hydroforming application for incoming design can be examined by cross sectional analyses and it is essential to ensure formability of tube material on every forming step such as pre-bending, preforming and hydroforming. At the die design stage, all the components of prototyping tool are designed and interference with press is checked by CAD. At the prototyping stage, prototyping technique is required to prevent various defects and to make good parts.