中文摘要：

为了实现铝合金副车架在某型国产高档轿车中的应用,对其副车架横梁的内高压成形过程进行实验研究。测量管件内典型截面在压弯、预成形以及内高压成形工序中的环向壁厚分布,分析截面的壁厚分布规律;建立管件内典型截面尺寸的正态概率分布函数,得到截面各尺寸相对于设计值的最大偏差。结果表明：对于膨胀量为2.63%的异形截面A-A,最大减薄位置位于长直边与左下圆角的过渡区,最大减薄率为15.6%;对于膨胀量为3.31%的矩形截面B-B,最大减薄位置位于长直边与右下圆角的过渡区,最大减薄率为15.8%。此外,截面A-A的最大尺寸偏差为0.19 mm,截面B-B的最大尺寸偏差为0.28 mm。两个典型截面的壁厚分布及尺寸精度均满足设计要求。

英文摘要：

In order to realize the application of aluminum sub-frame in domestic car, experimental researches were conducted to investigate the hydroforming process of the sub-frame. The thickness distribution On typical section of tubular parts along the circle direction during the press bending, preforming, and hydroforming processes was separately measured, and the thickness distribution rule was mainly discussed. Then, the normal distribution function based on statistical analysis for the geometry size of various sections was carried out, and the maximum dimensional deviation compared with the designed requirement was obtained. The results show that, the maximum thinning rate of the irregular section A-A with a expansion rate of 2.63% is 15.6%, which is located at the transition region between the long straight side and left bottom comer, and the maximum dimensional deviation is 0.19 mm. The maximum thinning rate of rectangle section B-B with a expansion rate of 3.31% is 15.8%, which is located on the transition region between the long straight side and right bottom comer, and the maximum dimensional deviation is 0.28 mm. Both the thickness distribution and dimensional accuracy meet the design requirements.