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A persistent problem with computer simulations of forming processes is a general lack of experimental verification. A project was undertaken to simulate the two-stage, aluminum tube hydroforming of a structural tee shape, and perform simultaneous experiments for comparison. The simulations, performed with the code LS-DYNA, were used to establish the initial process parameters and also to predict the shape and thickness profile of the final part. The simulations compared favorably to the experiments, and the results are presented.

It is often said that heavier cars are inherently safer than lighter ones. However, when all cars are built with steel, larger size necessarily implies greater weight, so it is unclear whether the improved safety correlates to the weight or size of the vehicle. Using a publicly available computer model of the Ford Taurus, it was thought that this perception could be tested. The existing steel model, with the addition of a Hybrid III dummy and driver side airbag, was validated against actual crash test data. The structure was converted to aluminum, structural stiffness was calculated, and the steel and aluminum crash simulation results were compared. The aluminum model, utilizing monocoque sheet structure, weld bonded joining, and tailor welded blanks, weighed 200 kg less than the steel model and performed as well.