scholarly journals Roller Design and Optimization Based on RSM with Categoric Factors in Power Spinning of Ni-Based Superalloy

2021 ◽  
Author(s):  
Zixuan Li ◽  
Xuedao Shu
Keyword(s):  
Single Point ◽  
Length Change ◽  
Nose Radius ◽  
Forming Process ◽  
Process Step ◽  
Power Spinning ◽  
Bite Angle ◽  
Installation Angle ◽  
Spinning Process ◽  
Conventional Spinning

Abstract Power spinning is a single point high pressure forming process which is usually studied with ideal regular billet. However, in some cases, the billet adopted in this process is from conventional spinning process with non-uniform wall thickness and springback. Therefore, the forming accuracy is low because this unpredictable spun billet. In this paper, cone, step and arc rollers are compared and the length change of deformation zone is calculated to further understand the forming mechanism of different roller shapes. Multi-step process simulation considering conventional spinning and power spinning is established. The influence of roller parameters such as roller nose radius, straightening zone in step roller and bite angle on the maximum roller force are discussed. In addition, the continuous factors such as installation angle and discrete factor roller shape are studied based on the response surface method (RSM) with categoric factors. The results show that roller shape have a big influence on the workpiece forming quality in power spinning process. Step roller is more suitable for use in this work. The roller nose radius and installation angle have great impacts on the maximum roller force.

Study on the Metal Flow in Power Spinning Process of Parts with Transverse Inner Rib

2011 ◽  
Vol 189-193 ◽  
pp. 2970-2975 ◽  
Author(s):  
Fei Ma ◽  
He Yang ◽  
Qiang Deng ◽  
Mei Zhan ◽  
Li Jin Hu
Keyword(s):  
Deformation Zone ◽  
Metal Flow ◽  
Plastic Deformation Zone ◽  
Fe Model ◽  
Forming Process ◽  
Precise Control ◽  
Power Spinning ◽  
Forming Defect ◽  
Spinning Process ◽  
Forming Defects

In this paper, by using a practical 3D FE model, one power spinning process of parts with transverse inner rib has been simulated. The stress and strain fields have been obtained and the features of metal flow in plastic deformation zone have been discussed thoroughly. Then, the main forming defects and their origins have been explored based on the study of the metal flow, shown as follows; (1) during the non-rib process, the main forming defect is the wall fracture in finished deformation zone. The origin of this forming defect is the excessive metal flow in thickness direction ahead of the forming roller. (2) in the rib-forming process, the main forming defect is the undesired inner rib. The origin of this forming defect is the excessive metal flow in hoop direction during the former non-rib process. (3) the features of the metal flow during flange part process are almost the same as those in the non-rib process. The achievements of this study can thoroughly reveal the deformation mechanism and provide an important basis for the optimization of the process parameters and the precise control of the power spinning process of parts with transverse inner rib.

Analysis of Conventional Spinning Process with Thermal Effects

2008 ◽  
Vol 594 ◽  
pp. 187-192 ◽  
Author(s):  
Chun Ho Liu ◽  
A Cheng Wang ◽  
Kuo Zoo Liang ◽  
Sheng En Hsu
Keyword(s):  
Heat Transfer ◽  
Thermal Effects ◽  
Mechanical Analysis ◽  
Forming Process ◽  
Transfer Energy ◽  
Conservation Of Energy ◽  
Explicit Finite Element ◽  
Mass Scaling ◽  
Spinning Process ◽  
Conventional Spinning

The temperature effect is significant on the metal forming processes; for the quality of products and the tools life are extremely affected by it. This paper investigates the thermal effects on the conventional spinning process by the explicit finite element method with transient heat transfer conditions. The governing equation is based on the updated Lagrangian formulation, the large deformation theory, and the principle of the conservation of energy. The energy terms in this study include the plastic strain energy, the frictional sliding energy, and the heat transfer energy. The energy and temperature distribution of the circular sheet, on the varying boundary conditions of the heat transformation, are discussed in detail. Furthermore, the various mesh types are examined in the simulations. With the application of the mass scaling factor technique, the full history of spinning process is performed successfully. The main benefit of the proposed model will save the tremendous costs in the die designing and the experimental works. The parameters and techniques using in the numerical model are helpful for the design of forming process and the coupling thermal-mechanical analysis.

Research on the Curvature Radius of Roller-Trace in the Forming Process of Conventional Spinning

2006 ◽  
Vol 532-533 ◽  
pp. 277-280
Author(s):  
Fei Ma ◽  
He Yang ◽  
Mei Zhan
Keyword(s):  
Compressive Stress ◽  
Selection Criterion ◽  
Critical Value ◽  
Curvature Radius ◽  
Fe Model ◽  
Forming Process ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Mandrel Diameter ◽  
Thinning Rate

Based on the 3D FE model of conventional spinning, the influence of curvature radius of roller-trace on the conventional spinning process has been studied. It is found that when the curvature radius of roller-trace is smaller, the maximum of thinning rate and hoop compressive stress increases dramatically with the increasing of the radius, and curvature radius does little effect on the forming process when it is up to a critical value. To obtain a more reasonable selection criterion of curvature radius of roller-trace, a new index named flange width has been put forward， which represents the comprehensive effect of workpiece diameter and mandrel diameter in the forming process of conventional spinning. Further research has been done and the selection criterion of curvature radius is obtained: the smaller the flange width is or the larger the workpiece thickness or the entry tangential angle is, the larger the range of reasonable curvature radius is.

scholarly journals Study on strong spinning preparation method and mechanism of the industrial pure titanium ultrafine crystallization

2019 ◽  
Vol 14 ◽  
pp. 155892501989525
Author(s):  
Yu Yang ◽  
Yanyan Jia
Keyword(s):  
Heat Treatment ◽  
High Performance ◽  
Pure Titanium ◽  
Grain Structure ◽  
Theoretical Research ◽  
Ultrafine Grain ◽  
Forming Process ◽  
Spinning Process ◽  
And Performance ◽  
Material Utilization

Ultrafine crystallization of industrial pure titanium allowed for higher tensile strength, corrosion resistance, and thermal stability and is therefore widely used in medical instrumentation, aerospace, and passenger vehicle manufacturing. However, the ultrafine crystallizing batch preparation of tubular industrial pure titanium is limited by the development of the spinning process and has remained at the theoretical research stage. In this article, the tubular TA2 industrial pure titanium was taken as the research object, and the ultrafine crystal forming process based on “5-pass strong spin-heat treatment-3 pass-spreading-heat treatment” was proposed. Based on the spinning process test, the ultimate thinning rate of the method is explored and the evolution of the surface microstructure was analyzed by metallographic microscope. The research suggests that the multi-pass, medium–small, and thinning amount of spinning causes the grain structure to be elongated in the axial and tangential directions, and then refined, and the axial fiber uniformity is improved. The research results have certain scientific significance for reducing the consumption of high-performance metals improving material utilization and performance, which also promote the development of ultrafine-grain metals’ preparation technology.

scholarly journals Artificial neural network for modeling and investigating the effects of forming tool characteristics on the accuracy and formability of thin aluminum alloy blanks when using SPIF

2021 ◽  
Author(s):  
Sherwan Mohammed Najm ◽  
Imre Paniti
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Process Parameters ◽  
Single Point ◽  
Tool Material ◽  
Deformation Mode ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Tool Shape ◽  
Artificial Neural

AbstractIncremental Sheet Forming (ISF) has attracted attention due to its flexibility as far as its forming process and complexity in the deformation mode are concerned. Single Point Incremental Forming (SPIF) is one of the major types of ISF, which also constitutes the simplest type of ISF. If sufficient quality and accuracy without defects are desired, for the production of an ISF component, optimal parameters of the ISF process should be selected. In order to do that, an initial prediction of formability and geometric accuracy helps researchers select proper parameters when forming components using SPIF. In this process, selected parameters are tool materials and shapes. As evidenced by earlier studies, multiple forming tests with different process parameters have been conducted to experimentally explore such parameters when using SPIF. With regard to the range of these parameters, in the scope of this study, the influence of tool material, tool shape, tool-end corner radius, and tool surface roughness (Ra/Rz) were investigated experimentally on SPIF components: the studied factors include the formability and geometric accuracy of formed parts. In order to produce a well-established study, an appropriate modeling tool was needed. To this end, with the help of adopting the data collected from 108 components formed with the help of SPIF, Artificial Neural Network (ANN) was used to explore and determine proper materials and the geometry of forming tools: thus, ANN was applied to predict the formability and geometric accuracy as output. Process parameters were used as input data for the created ANN relying on actual values obtained from experimental components. In addition, an analytical equation was generated for each output based on the extracted weight and bias of the best network prediction. Compared to the experimental approach, analytical equations enable the researcher to estimate parameter values within a relatively short time and in a practicable way. Also, an estimate of Relative Importance (RI) of SPIF parameters (generated with the help of the partitioning weight method) concerning the expected output is also presented in the study. One of the key findings is that tool characteristics play an essential role in all predictions and fundamentally impact the final products.

Geometry Compensation Methods for Increasing the Accuracy of the SPIF Process

2021 ◽  
Vol 883 ◽  
pp. 217-224
Author(s):  
Yannick Carette ◽  
Marthe Vanhulst ◽  
Joost R. Duflou
Keyword(s):  
Control Strategy ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Calculation Methods ◽  
Forming Process ◽  
Complex Deformation ◽  
Commercial Use ◽  
Compensation Methods ◽  
Deformation Mechanics

Despite years of supporting research, commercial use of the Single Point Incremental Forming process remains very limited. The promised flexibility and lack of specific tooling is contradicted by its highly complex deformation mechanics, resulting in a process that is easy to implement but where workpiece accuracy is very difficult to control. This paper looks at geometry compensation as a viable control strategy to increase the accuracy of produced workpieces. The input geometry of the process can be compensated using knowledge about the deformations occurring during production. The deviations between the nominal CAD geometry and the actual produced geometry can be calculated in a variety of different ways, thus directly influencing the compensation. Two different alignment methods and three deviation calculation methods are explained in detail. Six combined deviation calculation methods are used to generate compensated inputs, which are experimentally produced and compared to the uncompensated part. All different methods are able to noticeably improve the accuracy, with the production alignment and closest point deviation calculation achieving the best results

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

Experimental Investigation of Single Point Incremental Forming of Aluminum Sheet in Groove Test

2017 ◽  
Vol 867 ◽  
pp. 177-183 ◽  
Author(s):  
Vikrant Sharma ◽  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Experimental Investigation ◽  
Incremental Forming ◽  
Single Point ◽  
Fractional Factorial ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Backing Plate ◽  
Groove Test ◽  
Factorial Design Of Experiments ◽  
Tool Diameter

Incremental sheet forming is one of the latest processes in sheet metal forming industry which has drawn attention of various researchers. It has shown improved formability compared to stamping process. Single Point Incremental Forming (SPIF) process requires only hemispherical tool and no die is required hence, it is a die-less forming process. In this paper experimental investigation on SPIF for Aluminium sheet has been presented. A groove test on Vertical Machining Centre has been performed. Factors (Step depth, Blank holder clamping area, Backing plate radius, Program strategy, Feed rate and Tool diameter) affecting the process are identified and experiments are carried out using fractional factorial design of experiments. Effect of the factors on fractured depth, forming time and surface finish have been analyzed using Minitab 17 software.

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