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

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.

A method based on circumferential strain distribution for roller path design in conventional spinning of thin-walled conical part with curved surface

Multi-pass conventional spinning is the preferable forming technology for the forming of thin-walled conical part with curved surface (TCPCS) in aerospace field. In multi-pass conventional spinning, the design of roller path is a critical problem due to its sensitive effect on the deformation mode and forming defect during spinning process. However, at present, the roller path is still mainly designed based on experience and trial-and-error, which seriously restricts the high-performance spinning of TCPCS. In this work, a new quantitative method based on circumferential strain distribution was developed for the roller path design in multi-pass conventional spinning of TCPCS. In this method, the total required circumferential strain for the forming of final TCPCS by conventional spinning was firstly determined. Then, the spinning passes number were obtained through dividing the total required circumferential strain by the ultimate circumferential strain producing the spinning instability ( ε θult ). As for the roller path profile in each pass, it is divided into two sections and determined respectively, i.e. the attaching mandrel section and the performing section. The attaching mandrel section presents the same profile of mandrel. The profile of preforming section is determined point-by-point by distributing the rest of circumferential strain { ε θni } to produce the final TCPCS. The point-by-point distributed circumferential strain is half of the { ε θni } at the initial stage until reaches the half of ε θult , then it will keep the half of ε θult to the end. The proposed new method of roller path design was validated by finite element simulation, where well spinning stability, wall thickness distribution and roundness were obtained. This method provides a quantitative, high-efficient and universal way for the roller path design in conventional spinning of TCPCS.

Auxetic Yarn: Fundamentals, Influencing Parameters, Application Areas and Challenges

The mechanical behaviour of auxetic materials and structures is the most distinctive characteristic, which differs from that of conventional engineering materials due to the negative Poisson’s ratio. Auxetic materials have the fascinating feature of widening when stretched and contracting when compressed. In recent times, the research of auxetic materials based on textile structures has received a lot of interest. Auxetic effect development at the yarn phase is a new and exciting field of study. Many researchers already developed different types of auxetic yarns, such as the helical auxetic yarn, the plied auxetic yarn, the semi-auxetic yarn etc. The helical auxetic yarn (HAY) is the most commonly mentioned auxetic yarn. It is made up of a rigid wrap and an elastic core yarn. However, it is interesting that auxetic yarns can be produced from conventional non-auxetic fibres through the conventional spinning system as well. The helical auxetic yarn is a new type of yarn with a wide variety of possible applications. Moreover, pore-opening characteristics of auxetic yarns make it a potential candidate in the fields of technical textiles, such as medical textiles, filter application, protective textiles etc. Fabrication of auxetic textiles by utilizing auxetic yarns through simple weaving and knitting technology opens the door to new applications. The aim of this paper is to address the fundamentals of auxetic yarns, such as structure, shortcomings, production techniques, as well as the influencing process parameters. From various research works, it is evident that the wrap helical angle, the core/wrap diameter ratio, and the initial moduli of wrap component are the most vital processing parameters during the production of auxetic yarns. Finally, some potential application areas and challenges of auxetic yarns are also addressed briefly in this paper.