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 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.

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.

Determination of formability considering wrinkling defect in first-pass conventional spinning with linear roller path

2019 ◽  
Vol 265 ◽  
pp. 44-55 ◽  
Author(s):  
S.W. Chen ◽  
P.F. Gao ◽  
M. Zhan ◽  
F. Ma ◽  
H.R. Zhang ◽  
...  
Keyword(s):  
Roller Path ◽  
First Pass ◽  
Conventional Spinning

Research on Ultimate Thinning Rate of Superalloy Spinning

2021 ◽  
Vol 1035 ◽  
pp. 152-160
Author(s):  
Hai Bao Wu ◽  
Fu Long Chen ◽  
De Gui Liu ◽  
Ji Zhen Li ◽  
Jian Fei Wang
Keyword(s):  
High Temperature ◽  
Process Parameters ◽  
Middle Level ◽  
Feed Ratio ◽  
Forming Limit ◽  
Body Parts ◽  
Influence Of Process Parameters ◽  
Process Guidance ◽  
Spinning Process ◽  
Thinning Rate

Spinning forming is an effective method for processing thin-walled rotating body parts. The influence of process parameters on the spinning forming limit of materials was studied for the four high-temperature alloys of GH3044, GH3625, GH3536 and GH4169 used in aero-engines. The results can be used as aero-engine high-temperature alloy parts spinning process and provides experimental basis and process guidance. The research results showed that the forming temperature had a significant effect on the spinning forming performance of superalloy materials. When the temperature increased to 800°C and above, the ultimate thinning rate raised 70%. The ultimate thinning rate of GH4169 was higher than the other three materials and GH3044 and GH3536 was at the middle level, GH3625 was relatively low. At the same time, the feed ratio and the corner radius of the rotary wheel had a certain influence on the ultimate thinning rate of different superalloys. The spinning process needs to select reasonable process parameters according to the actual situation when the spinning is applied to manufacture parts.

Numerical and Experimental Analysis of Attaching-Mandrel Process Under Multi-Pass Cold Spinning Process on Superalloy GH3030

2019 ◽  
Author(s):  
Li Zixuan ◽  
Shu Xuedao ◽  
Cen Zewei ◽  
Zhang Song
Keyword(s):  
Production Efficiency ◽  
Thickness Distribution ◽  
Grain Structure ◽  
Combination Method ◽  
Nickel Base Superalloy ◽  
Forming Quality ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Hot Spinning Process ◽  
Nickel Base

Abstract The superalloy products formed by multi-pass conventional spinning are widely used in rotary forming parts with complex shapes. As the connection of each forming pass, the attaching-mandrel process has an important influence on forming quality and production efficiency. The hot spinning process is usually adopted in superalloy forming because its poor plasticity in normal temperature, meanwhile, it brings the poor surface quality of the parts and huge energy consumption. For this reason, the cold spinning and the attaching-mandrel process of nickel-base superalloy GH3030 are studied. The combination method of experiment and simulation is used to study the attaching-mandrel process based on one-forward-pass spinning process. The effects of pass pitch and the attaching-mandrel velocity on the tool forces, parts stress field, strain field and wall thickness distribution are analyzed. The microstructure of the part is divided into three layers: outer, middle and inner layer. The grain size of each layer is compared. Then the effect of different pass pitch on the grain structure is clarified. The results show that the reasonable pass pitch and the attaching-mandrel velocity can improve the forming quality and production efficiency. The multi-pass cold spinning process on superalloy GH3030 is feasible. The excessive pass pitch can cause seriously grain elongation, the grain boundaries are blurred, and even cracking.

scholarly journals Study on Spinning Process Parameters of the Copper Bushing by Tribological Properties and Physical Testing

2021 ◽  
Vol 2083 (2) ◽  
pp. 022084
Author(s):  
Xiaolu Hong ◽  
Hengqiu Xu ◽  
Ying Xu ◽  
Tao Huang ◽  
Yaming Guo ◽  
...  
Keyword(s):  
Fatigue Resistance ◽  
Process Parameters ◽  
Tribological Properties ◽  
Thermal Simulation ◽  
Feed Ratio ◽  
Mechanical Parts ◽  
Good Strength ◽  
Physical Testing ◽  
Spinning Process ◽  
Thinning Rate

Abstract The bushing is a kind of ring sleeve which acts as a liner outside the mechanical parts, which needs good strength, hardness and fatigue resistance. In this paper, the copper bushing was prepared by spinning forming method, and the process parameters of spinning were explored. According to the results of material thermal simulation and test, the conclusion is that the spinning process of copper bushing needs to be carried out in two passes by reverse spinning method. The thinning rate is 30% and 25% respectively. The gap between the mandrel and the roller is 10mm, the feed ratio is 1mm/r, and the spinning temperature is 250°C.

Involute Curve Roller Trace Design and Optimization in Multipass Conventional Spinning Based on the Forming Clearance Compensation

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Zixuan Li ◽  
Xuedao Shu
Keyword(s):  
Strain Distribution ◽  
Production Efficiency ◽  
Trial And Error ◽  
Design And Optimization ◽  
Conventional Spinning ◽  
Trial And Error Method ◽  
Set Up ◽  
Involute Curve ◽  
The Mathematical Model ◽  
Error Method

In industrial production, the roller trace design is still based on the trial-and-error method that is more like an art than science. In this paper, we establish the mathematical model of the involute curve roller trace and adopted the forming clearance compensation in the attaching-mandrel process. The backward pass roller trace is optimized to avoid the roller interference due to blank springback. The spinning simulation model of seven forming passes is set up and verified by the experiments with superalloy GH3030. The wall thickness, the strain distribution, and the tool forces are analyzed. The results show that the forming clearance compensation can greatly shorten the forming time and enhance the production efficiency and saving energy. The metal accumulates at the edge of the blank, and the maximum thinning zone appeared near the edge and is prone to crack. In the straightening pass, the tool forces of both the roller and the mandrel are larger than those in the other passes.

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