Applications of hydroforming processes to automobile parts

Hydroforming process recently draws attention of automotive industries due to its advantages like the increased strength, weight reduction, improved quality and reduced tooling cost. This paper summarizes some of our experiences of tube and sheet hydroforming process design by simulation technique through actual tryout. Parts included in this paper are tie bar, subframe and engine mount bracket. The simulations for the entire hydroforming processes were performed and their results were used to predict and fix the forming failures like the wrinkling and the fracture. Based on this experience, we also suggested necessary improvements in the design procedure.