Numerical simulation of hydroforming hollow crankshaft

An investigation was conducted on how to control loading path and its effect on thickness distribution after hydroforming crankshaft by using finite element simulation. Four different loading paths were utilized in simulating the forming process of hydroforming crankshaft and the results of different loading paths were presented. It shows that the hydroforming is dependent on the appropriate loading path. There exists the zone of hydroforming process window which can be confirmed by using simulation method. Wrinkles occur as the the internal pressure is less than 20MPa and bursting occurs as the the internal pressure is larger than 32MPa. Only when the internal pressure locates between 20MPa and 30MPa, can an eligible crankshaft component be manufactured.