scholarly journals AN INVESTIGATION INTO A CONVENTIONAL SPINNING PROCESS COMBINED WITH FLOW FORMING WITH SIMULTANEOUSLY BURNISHING PROCESSES

2021 ◽  
Vol 40 (1) ◽  
pp. 97-107
Author(s):  
K. Atia ◽  
S. El-Abden ◽  
M. El-Sheikh ◽  
W. Marzouk
Keyword(s):  
Flow Forming ◽  
Spinning Process ◽  
Conventional Spinning

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 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.

A review of conventional and modern single-point sheet metal forming methods

2003 ◽  
Vol 217 (2) ◽  
pp. 213-225 ◽  
Author(s):  
E Hagan ◽  
J Jeswiet
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Single Point ◽  
Small Region ◽  
Numerical Control ◽  
Localized Deformation ◽  
Flow Forming ◽  
Conventional Spinning ◽  
Forming Methods

The use of computers in manufacturing has enabled the development of several new metal forming processes that are based upon older technologies. In this case modifications have been made to traditional forming methods such as conventional spinning and shear forming. These two processes are similar in that the deformation mechanism is localized to a small region under the forming tool. Recent advances in computing power have enabled this localized deformation to be accurately controlled and studied. Spinning, shear forming and flow forming are limited to forming parts that are symmetrical about the revolving lathe axis. Current research has been focused on forming non-symmetrical parts using computer numerical control (CNC) technology, without the need for costly dies. A comparison of traditional and modern forming methods is presented here in an attempt to illustrate the evolution of different incremental sheet metal forming techniques. Emphasis is placed on conventional spinning, shear forming and modern computer-controlled forming methods that are currently being studied.

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.

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.

Mechanical Properties and Microstructure of A356-T6 Aluminum Alloy Wheel Hub Based on Casting-Spinning Process

2021 ◽  
Vol 1036 ◽  
pp. 3-10
Author(s):  
Zhang Feng Wang ◽  
Chi Xiang Ou ◽  
Meng Jun Wang ◽  
Bai Chen Chen ◽  
Gang Xian Fan
Keyword(s):  
Mechanical Properties ◽  
Fracture Morphology ◽  
Tensile Tests ◽  
Eutectic Structure ◽  
Forming Process ◽  
Flow Forming ◽  
Eutectic Region ◽  
Factors Affecting ◽  
Spinning Process ◽  
Upper Rim

The mechanical properties and microstructure of the A356-T6 wheel hub based on low pressure die casting-hot flow forming process were analyzed by means of optical microscopy (OM), scanning electron microscopy (SEM) and tensile tests. Results showed that the size of the eutectic region and the morphology of the Si phase were the main factors affecting the mechanical properties and fracture morphology of the wheel hub. There was a uniform distribution of eutectic area and fine Si phase morphology in the microstructure of the upper rim and lower rim, moreover, the ultimate tensile strength and yield strength of the upper rim reached 282.4MPa and 185.1MPa, respectively. The fractures were mainly composed of fine quasi-cleavage platform and dimple. The microstructure of the rim showed a long strip along the deformation direction and the eutectic structure and Si particles were uniformly distributed. Irregular polygonal eutectic regions and coarse rod-like Si particles were accumulating in the spoke, causing a serious decrease in mechanical properties, especially in the spoke center and spoke R angle.

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.

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.

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.

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