空心双拐曲轴内高压成形数值模拟

应用动态显式有限元法对空心双拐曲轴的内高压成形过程进行了模拟分析,研究了加载路径对内高压成形的影响,指出了在加载曲线中存在着最佳成形区间,成形压力小于20MPa时,管坯产生起皱,成形压力大于32MPa时,管坯发生开裂,只有合理的应用加载路径,成形压力介于20MPa与30MPa之间,使轴向进给量可以正好补偿径向的变形量才能获得壁厚较为均匀的合格零件。

Numerical simulation of hydroforming hollow crankshaft components

The hydroforming technology is widely used today in the mass production of light weight components for the industry.Hydroforming is a manufacturing process which involves the use of internal pressure and axial loads to reshape components in a specially designed die piece.The internal pressure and axial feeding are defined as a function of time,and usually referred to as loading paths.Finite element analysis has been proven to be a useful tool for hydroforming process analyses.Hydroforming process simulation greatly reduces the development time and prototyping cost.In this paper,an investigation is conducted how to control loading path and its effect on thickness distribution after hydroforming crankshaft by using finite element simulation.Four different loading paths are utilized in simulating the forming process of crankshaft with hydroforming and the results of different loading paths are presented.It shows that the hydroforming is dependent on the appropriate loading path.It exists the zone of hydroforming process window can be confirmed by using simulation method.Wrinkles occurs as the internal pressure <20 MPa and bursting occurs as the the internal pressure > 32 MPa.Only this internal pressure locates between 20MPa~30MPa,an eligible crankshaft component can be manufactured.