Study on Spinning Process of a Thin-Walled Aluminum Alloy Vessel Head With Small Ratio of Thickness to Diameter

2010 ◽  
Vol 132 (1) ◽  
Author(s):  
Yanqiu Zhang ◽  
Debin Shan ◽  
Wenchen Xu ◽  
Yan Lv
Keyword(s):  
Aluminum Alloy ◽  
Feed Ratio ◽  
Small Range ◽  
Factors Affecting ◽  
Small Ratio ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Thin Walled ◽  
Line Trajectory ◽  
Blank Size

The thin-walled vessel head with the ratio of thickness to diameter less than 3‰ has long been considered to be difficult to be spun because wrinkling is very likely to occur during the thin-walled vessel head spinning process when the thickness is far smaller than the diameter. Based on process experiments and finite element method, the spinning failure of thin-walled vessel head with a small ratio of thickness to diameter is analyzed in the present research. The mechanism of wrinkling is identified and some effective solutions are discussed to prevent the failure. The results show that the feed ratio, the blank geometry, and the roller trajectory are the main factors influencing the spinning qualities. In the shear spinning, the feasible roller feed ratio is found to be within a very small range because of the thin thickness of blanks. Wrinkling will occur if the feed ratio is slightly outside the operation range. Bending the edge of blank or enlarging the blank size can effectively prevent wrinkling at a larger feed ratio, which would increase the operation range of roller feed ratio. Due to the fact that the conventional spinning is a process of multiple passes, there are many factors affecting the forming quality of thin-walled aluminum alloy vessel head. Wrinkling is likely to happen by the influence of roller trajectory in the first pass due to the fact that the thickness of blank is far smaller than the diameter. The straight-line trajectory is the worst trajectory under which wrinkling is most likely to occur.

Experimental Study of Factors Affecting the 7075 Aluminum Alloy Thin-walled Parts Milling Force

2016 ◽  
Vol 10 (8) ◽  
pp. 29-34
Author(s):  
Fengyun Yu ◽  
Lin Wu ◽  
Yunliang Fu ◽  
Yanyan Guo ◽  
Can Zhao ◽  
...  
Keyword(s):  
Experimental Study ◽  
Aluminum Alloy ◽  
7075 Aluminum Alloy ◽  
Milling Force ◽  
Factors Affecting ◽  
Thin Walled

scholarly journals Effects of the roller feed ratio on wrinkling failure in conventional spinning of a cylindrical cup

2011 ◽  
Vol 225 (11) ◽  
pp. 1991-2006 ◽  
Author(s):  
L Wang ◽  
H Long ◽  
D Ashley ◽  
M Roberts ◽  
P White
Keyword(s):  
Finite Element ◽  
Simulation Models ◽  
Feed Ratio ◽  
Forming Limit ◽  
Explicit Finite Element ◽  
Shell Elements ◽  
Computational Performance ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Cylindrical Cup

In this study, wrinkling failure in conventional spinning of a cylindrical cup has been investigated by using both finite element (FE) analysis and experimental methods. FE simulation models of a spinning experiment have been developed using the explicit finite element solution method provided by the software Abaqus. The severity of wrinkles is quantified by calculating the standard deviation of the radial coordinates of element nodes on the edge of the workpiece obtained from the FE models. The results show that the severity of wrinkles tends to increase when increasing the roller feed ratio. A forming limit study for wrinkling has been carried out and shows that there is a feed ratio limit beyond which the wrinkling failure will take place. Provided that the feed ratio is kept below this limit, the wrinkling failure can be prevented. It is believed that high compressive tangential stresses in the local forming zone are the causes of the wrinkling failure. Furthermore, the computational performance of the solid and shell elements in simulating the spinning process are examined and the tool forces obtained from wrinkling and wrinkle-free models are compared. Finally, the effects of the feed ratio on variations of the wall thickness of the spun cylindrical cup are investigated.

Sealing-Spinning Technology for Thin-Walled Aluminum Alloy Tubes

2011 ◽  
Vol 221 ◽  
pp. 259-263
Author(s):  
Li Xia Sun ◽  
Jian Bo Jia ◽  
Yan Xu ◽  
Sheng Yuan Jiang
Keyword(s):  
Aluminum Alloy ◽  
Wall Thickness ◽  
Feed Rate ◽  
External Environment ◽  
Geological Exploration ◽  
Technical Parameters ◽  
Spinning Process ◽  
Thin Walled ◽  
Scientific Value

Thin-walled aluminum alloy tubes can be used as rigid sampling tubes in aerospace and geological exploration and other scientific researches. In order to ensure the scientific value of samples and isolate the external environment, two sealing ends of the rigid sampling tubes are required. In this paper, the sealing-spinning process is adopted to form two sealing ends of the thin-walled aluminum alloy tubes. The results show that rigid sampling tubes with good sealing quality can be formed by controlling the main technical parameters of sealing-spinning process. And the relationships between spinning load and feed rate of roller, spinning load and shape of roller, reducing ratio of wall thickness and feed rate of roller are found.

Heat Spinning Deformation Technology of 7A04 Loading-Wheel

2013 ◽  
Vol 652-654 ◽  
pp. 1988-1993
Author(s):  
Heng Qiu Xu ◽  
Ming Zhe Li ◽  
Lin Lin Li ◽  
Rui Zhang ◽  
Da Li Wang ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Performance Test ◽  
Mechanical Performance ◽  
Alloy Sheet ◽  
Aluminum Alloy Sheet ◽  
Internal Organization ◽  
Forming Technology ◽  
Spinning Process ◽  
Conventional Spinning

The program 7A04 aluminum alloy loading-wheels spinning process is described briefly. It formulates the process parameters of aluminum alloy loading-wheels spinning. It uses the aluminum alloy sheet heat spinning process. It analyzes conventional spinning preformed and spinning flanging forming technology regulation. It studies the lubricating technology in the spinning process. The cracking problem is analyzed and solved in the spinning process. The mechanical performance test and the internal organization of the inspection are detected. The finished product meets the requirements. The small batch loading-wheels are produced, which lay the foundation for large quantities loading-wheel spinning production for future.

scholarly journals Experimental Investigation on the Geometrical Accuracy of the CNC Multi-Pass Sheet Metal Spinning Process

2018 ◽  
Vol 2 (3) ◽  
pp. 59 ◽  
Author(s):  
Mohamed Abd-Alrazzaq ◽  
Mahmoud Ahmed ◽  
Mohamed Younes
Keyword(s):  
Sheet Metal ◽  
Feed Ratio ◽  
Shape Accuracy ◽  
Factors Affecting ◽  
Geometrical Accuracy ◽  
Computer Numerically Controlled ◽  
Spinning Process ◽  
High Feed ◽  
Metal Spinning ◽  
Localized Plastic Deformation

The geometrical accuracy of multi-pass sheet metal spinning products is crucial in many applications. Aerospace, petroleum, and chemical industries motivated the development of modern spun components of complicated shapes with special functionality, but a substantial research lag exists behind this progress. Due to the localized plastic deformation involved, careful control of dimensions and form is required in spinning procedures. In this study, two sets of experiments were implemented for cup manufacturing using a retrofitted computer numerically controlled (CNC) spinning machine to identify the critical factors affecting product geometry and reveal their influence on the shape accuracy of the spun cups. The first set is a screening experiment to determine the most significant parameters and the second provides the optimum processing conditions affecting cup quality. The feed ratio, number of spin-forming passes, spinning ratio, and lubrication were found to have the most important effect on the geometry of the spun cups. Optimum quality with a higher processing speed (productivity) was achieved under a lubricated condition using a larger number of spin-forming passes at a high feed ratio, diminishing the commonly adopted rule of slow spinning for accurate products and reflecting a significance for state-of-the-art spinning practice. The findings of this paper introduce a basis for a spinning quality database.

Study of Dieless Radial Spinning for Thick-Walled Cylindrical Parts With External Grooves

2021 ◽  
Author(s):  
Famei Liu ◽  
Junsong Jin ◽  
Wei Rao ◽  
Ying Wang ◽  
Chang Gao ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Forming Process ◽  
Forming Quality ◽  
Spinning Process ◽  
Cylindrical Parts ◽  
Forming Characteristics ◽  
Thin Walled ◽  
Aluminum Alloy Tube ◽  
Orthogonal Tests

Abstract Thick-walled cylindrical parts with external grooves are common components in the automobile and aviation fields. Such components can be produced by pressing the outer surface of a spinning thick-walled aluminum alloy tube by the dieless radial spinning process. The forming characteristics in the spinning process and the effects of various process parameters on forming were studied by using orthogonal tests and finite element simulations. During the forming process, bulge and thickness reductions occur because of material flow. The results of an investigation of process parameter effects show that the stress yield ratio (ξ) had no significant effect on forming. However, the feed thickness ratio (η) and initial wall thickness of the tube (t0) crucially affected the forming quality (e.g., the heights of bulges and thickness reduction in the groove area). Thick-walled tubes presented different phenomena compared to the thin-walled.

Roller Trace Design in Multi-Pass Conventional Spinning Based on Cylindrical Part

2020 ◽  
Author(s):  
Li Zixuan ◽  
Shu Xuedao ◽  
Ye Bohai ◽  
Wang Jitai
Keyword(s):  
Cylindrical Part ◽  
Feed Ratio ◽  
Thickness Uniformity ◽  
First Pass ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Thickness Variations ◽  
Product Thickness ◽  
Trace Curves ◽  
Involute Curve

Abstract Conventional spinning is a kind of ancient revolving process which controls the product’s shape by roller trace design. It is also widely used in civil, military, automobile, aerospace and other fields. Unlike the power spinning process, the roller trace used in conventional spinning is complex. Both thickness uniformity and crack defects are affected by it. However, roller trace design is still based on experience without a solid theoretical basis. This paper simulated five different roller trace curves: involute curve, circular curve, Bezier curve, conchoids and line. Experiments using superalloy GH3030 were conducted in conjunction with a multi-pass conventional spinning simulation model. Blank thickness variations, mandrel and roller forces of different roller traces in the first pass are analyzed and assessed through the verification experiments. The results suggest that the curve trace parameters play a key role on the product thickness uniformity. And the distribution of Bezier and conchoid roller traces is more uniform than the other traces. The axial force of mandrel is a very important factor in the design of tool load capability. Larger roller feed ratio and proper roller traces can reduce the thinning which may avoid the cracks.

scholarly journals Factors Affecting the Compression and Energy Absorption Properties of Small-Sized Thin-Walled Metal Tubes

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Xiaoqin Hao ◽  
Jia Yu ◽  
Weidong He ◽  
Yi Jiang
Keyword(s):  
Energy Absorption ◽  
Simulation Models ◽  
Simulation Method ◽  
Engineering Practice ◽  
Small Ring ◽  
Metal Tube ◽  
Absorption Properties ◽  
Factors Affecting ◽  
Thin Walled ◽  
Hollow Metal

To solve the problem of the effective cushioning of fast-moving mechanical components in small ring-shaped spaces, the factors affecting the compression and energy absorption properties of small-sized hollow metal tubes were studied. Simulation models were constructed to analyse the influences of tube diameter, wall thickness, relative position, and number of stacked components on the compression and energy absorption properties. The correctness of the simulation method and its output were verified by experiments, which proved the effectiveness of compression and energy absorption properties of small-sized thin-walled metal tubes. The research provides support for the application of metal tube buffers in armament launch technology and engineering practice.

scholarly journals Elastic, inelastic and time constant measurement for M102 (AL–C–O) dispersions-reinforced aluminum alloys

2020 ◽  
pp. 61-66
Author(s):  
Khaleel Abushgair
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Time Constant ◽  
Room Temperature ◽  
Strain Range ◽  
Time Interval ◽  
Cnc Milling ◽  
Plastic Deformations ◽  
Factors Affecting ◽  
Bulk Content

Purpose. To conduct an experimental study on M102 aluminum alloy bulk content characterization under cyclic loadings for precision applications such as balance machines, optical, and laser instruments. M102 (AL-C-O) dispersion-reinforced aluminum alloy was chosen because of its ability to withstand temperatures beyond 200C and has a better strength than precipitation-hardened Al alloys at room temperature. A CNC milling machine is used to manufacture test samples with longitudinal machining directions. A constant time interval is set for the fabric a quarter-hour span, which is based on the investigation of inelastic and plastic deformations in the nanoscale. Methodology. An electromagnetic test instrument applies a tensile stress range of 10 to 145 N/mm2 to samples with particular shape. It should be noted that interferometers and capacitive sensors were used to measure all forms of deformations with and without loading. The experiments are carried out in a temperature-stable environment of 30.5 C; measurements are taken within a residual strain range of 10 microns. Findings. The results obtained show that results for inelastic deformations for samples of longitudinal cuts direction at 30.5 C were measured under 150 N/mm2 stress as 500 nm inelastic deformation and 100 nm plastic deformation were measured, which is much higher than aluminum alloy studied before at room temperature (20 C). Furthermore, it was found that the time constant of the M102 (ALCO) aluminum alloy samples was double times higher than that for other samples, Originality. For the first time, a study has been conducted on inelastic and plastic deformations in the nanoscale for characterization of M102 aluminum alloy bulk content under cyclic loadings for precision applications. Practical value. One of the main factors affecting the using of other materials than steel in precision applications such as balance machines, optical, and laser instruments is measurement and determination of inelastic, plastic and time constant of the process of delamination of materials of different aluminum alloys since they are nonmagnetic, are easily machined and shaped. This will bring new products and opportunities for these materials.

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