This paper on "Prediction of Failure During Hydroforming Processes Analytical Investigation of Tube Hydroforming Limits" was presented at the NAFEMS World Congress on The Evolution of Product Simulation From Established Methods to Virtual Testing & Prototyping - 24-28 April 2001, The Grand Hotel, Lake Como, Italy.

Abstract

As the demand concerning lightweight vehicle design and part precision increases, there is still an interest in new process - which are capable of manufactured parts having the desired properties (mechanical, geometric and surface). Tube Hydroforming is one process which can be used to fit these demands. It provides a number of advantages in comparison to conventional stamping or deep drawing processes including part reduction [1], reduction of tooling and material costs [2]. As a result, the technology has drawn increasing acceptance in the automotive industry during the last years for making a wide variety of structural components like rear axle carriers, engine cradles and frame parts for the body in white. However, not only the process control is rewarded, not the sole existence of a prototyping part is seen as a sensation, but best productivity, lowest production costs of the whole manufacturing line, and last but not least increased part quality is expected and assumed. The major advantages of tube hydroforming that have motivated these applications are cost and weight savings, improved component dimensional stability, better structural integrity and increased strength and stiffness.