Simulation of Pipe Hydroforming

The importance of investigating the formation of a torsion beam and understanding how it can be manipulated to perform at an optimum condition is crucial to car manufacturers. Developing and remodelling the torsion beam can allow both a simpler structure and quicker assembly while reducing the space required for a car suspension’s system, thus saving time and costs for manufacturers. Nowadays, the use of hydroforming technology has become widespread because it is able to obtain complex hollow parts more easily and has been continually developed to become a globally applied technology in the formation of a torsion beam of a vehicle. With regards to the current issues in academic research and real-world production, this research uses a finite element analysis (FEA) method-based software tool DYNAFORM, to simulate the pipe hydroforming process in order to show the overall manufacturing process, thus providing a precise FEA simulation model of a torsion beam suspension for the automotive manufacturing. This will also provide a math model (a regression equation) for further research and the further application of this technology in the future