A Study on Design of Forming Process of Tube-end for Brake of Automobiles

자동차 브레이크용 튜브의 끝단 성형 공정 설계에 관한 연구

End part of the brake tube formed with the shape of snake head is important for the braking of automobile in safety because it has to prevent crack, fracture and defects occurred during the forming process. Especially, the shape of tube end has influence on the ability of brake. Based on the procedure of process design, in this paper, the forming operation is done by finite element method and the design variables are analyzed by Taguchi method. Design variables such as the outer angle of tube end with the shape of snake head(A), the inner angle to make a hole at tube end with the shape of snake head(B) and the forming distance at tube end(C) are used. Optimization of design variables is performed to minimize the damage factor of the tube end occurred during the forming process. The value of damage factor of 0.327 was obtained under the optimal condition like $A=114^{\circ},\;B=80^{\circ}$ and C=5.3mm, respectively.