Development of Front side member by Hydroforming

In this paper, we investigate a forming process and formability of the hydroformed front side member designed in the ULSAB-AVC project. The forming process consists of bending, preforming and hydroforming. We carried out a feasibility study of these processes by FEM analysis. We then found a path by which we could form the front side member without it buckling or bursting. In addition, because the front side member designed in the ULSAB-AVC project is a highly specific one, we designed a front side member more generic to actual car body structures. We carried out trials and evaluations of the crash absorption energy of this generic front side member using various thicknesses and strengths of tubes and tailored tubes.