Chapter 15
Simulation of Multi-step Tube Hot Gas
Forming Process of a UHSS Torsion
Beam
Shangwen Ruan, Jianping Zhao, Zhenli Mi, Lan Su, and Pengzhi Cheng
Abstract Ultra-high strength steel can significantly improve the safety and
lightweight of vehicles, especially for the closed-profile components. In this study,
a novel process simulation of multi-step tube hot metal gas forming (HMGF) of a
V-shape torsion beam is conducted. The aim of this paper is to provide the insight into
the influence of process variables, such as pre-heating condition, gas pressure and
tool temperature, on the formability, hardening and component behavior. The press
hardening steel used is hot-rolled BR1500 steel and the stress-strain relationships
under different temperatures are investigated for the thermo-mechanical simulation.
A consistent simulation model with all relevant sub-stages is then established in LSDYNA software. Component geometry, wall thinning, hardness and microstructure
distributions are achieved in the simulation and the forming parameter dependency is
analyzed. And the forming equipment is introduced. The hot gas forming step is the
most complicated process, and is carried out in a nitrogen gas environment, which
prevents oxidation of the parts after heating.
Keywords Ultra-high strength steel · Tube hot gas forming · Torsion beam ·
Multi-step forming
S. Ruan · Z. Mi (B) · L. Su
Institute of Engineering Technology, University of Science and Technology Beijing, Beijing
100083, China
e-mail: mizl@nercar.ustb.edu.cn
J. Zhao
Guangxi Automobile Holdings Limited, Liuzhou 545000, China
P. Cheng
Hangyu Intelligent Manufacture Limited, Beijing 100089, China
© The Author(s), under exclusive license to Springer Nature Switzerland AG 2021
J. Xu and K. M. Pandey (eds.), Mechanical Engineering and Materials,
Mechanisms and Machine Science 100,
https://doi.org/10.1007/978-3-030-68303-0_15
183
Simulation of Multi-step Tube Hot Gas
Forming Process of a UHSS Torsion
Beam
Shangwen Ruan, Jianping Zhao, Zhenli Mi, Lan Su, and Pengzhi Cheng
Abstract Ultra-high strength steel can significantly improve the safety and
lightweight of vehicles, especially for the closed-profile components. In this study,
a novel process simulation of multi-step tube hot metal gas forming (HMGF) of a
V-shape torsion beam is conducted. The aim of this paper is to provide the insight into
the influence of process variables, such as pre-heating condition, gas pressure and
tool temperature, on the formability, hardening and component behavior. The press
hardening steel used is hot-rolled BR1500 steel and the stress-strain relationships
under different temperatures are investigated for the thermo-mechanical simulation.
A consistent simulation model with all relevant sub-stages is then established in LSDYNA software. Component geometry, wall thinning, hardness and microstructure
distributions are achieved in the simulation and the forming parameter dependency is
analyzed. And the forming equipment is introduced. The hot gas forming step is the
most complicated process, and is carried out in a nitrogen gas environment, which
prevents oxidation of the parts after heating.
Keywords Ultra-high strength steel · Tube hot gas forming · Torsion beam ·
Multi-step forming
S. Ruan · Z. Mi (B) · L. Su
Institute of Engineering Technology, University of Science and Technology Beijing, Beijing
100083, China
e-mail: mizl@nercar.ustb.edu.cn
J. Zhao
Guangxi Automobile Holdings Limited, Liuzhou 545000, China
P. Cheng
Hangyu Intelligent Manufacture Limited, Beijing 100089, China
© The Author(s), under exclusive license to Springer Nature Switzerland AG 2021
J. Xu and K. M. Pandey (eds.), Mechanical Engineering and Materials,
Mechanisms and Machine Science 100,
https://doi.org/10.1007/978-3-030-68303-0_15
183