基于内高压成形的副车架管梁逆向重构降内压研究

On the premise of forming accuracy, in order to achieve low hydroforming pressure design of hydroformed parts and reduce production costs, a forward design and reverse reconstruction design method for low hydroforming pressure for a certain subframe hydroforming tubular beam was proposed, which involves applying forward design technology to complete the structural design of the hydroformed tubular beam. It is determined that the hydroforming pressure with higher level of 205 MPa can ensure the forming accuracy of the tubular beam by numerical simulation technology. High hydroforming pressure is not conducive to control the production cost of the hydroformed tububar beam. Using reverse reconstruction technology to complete reverse reconstruction of the tubular beam, its forming accuracy under hydroforming pressure of 95 MPa can reach the forming accuracy level of the initial model under hydroforming pressure of 205 MPa. Based on reverse reconstruction model of tubular beam, sample trial production and process testing were completed, which verificed the correctness of the simulation result. Compared with the simulation results of the initial model under hydroforming pressure of 205 MPa, the tubular beam can meet the forming accuracy requirements under hydroforming pressure of 95 MPa using reverse reconstruction technology, ultimately achieving the reduction of hydroforming pressure by 53. 7%, and the reduction the of maximum mold fitting deviation by 25. 0%, and the minimum wall thickness increases by 2. 9%. The subframe assembly using hydroformed tubular beam ultimately passed the 150% durability assessment in bench tests.