Process optimisation and robustness analysis for HFQ process

Abstract Lightweight materials and lightweight technologies have gained significant attention from all EV vehicle manufacturers. Aluminium has been commonly used as a replacement for steel in the automotive industry many years. High-strength aluminium alloys high specific strength, their formability increases significantly at elevated temperatures. New manufacturing incorporating temperature forming emerged recently, allowing of ultrahigh-strength alloys. One such technology is Hot Form Quench (HFQ)® which process that combines with virtually no springback (ultra)-high-strength The thermal expansion approximately twice steel, leading to material contraction during in-die quenching. This especially pronounced large or long components. Therefore, robustness analysis parameters can be optimise enable capable production parts meeting dimensional specification requirements. Such performed using AutoForm-Sigma solver this paper presents simulation methodology developed AutoForm its use verify accuracy distortion prediction one safety cell structure A sensitivity implemented improve robustness.