Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads

doi:10.1007/s40436-020-00296-0

Advances in Manufacturing ›› 2020, Vol. 8 ›› Issue (2): 189-203.doi: 10.1007/s40436-020-00296-0

Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads

Yong-Cheng Lin^1,2,3, Jia-Yang Chen^1,2, Dao-Guang He^1,2, Xin-He Li^1,3, Jian Yang³

1 School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, People's Republic of China;
2 State Key Laboratory of High Performance Complex Manufacturing, Changsha 410083, People's Republic of China;
3 Light Alloy Research Institute, Central South University, Changsha 410083, People's Republic of China

收稿日期:2019-08-16 修回日期:2020-01-02 出版日期:2020-06-25 发布日期:2020-06-08
通讯作者: Yong-Cheng Lin E-mail:yclin@csu.edu.cn
基金资助:
This work was supported by the National Natural Science Foundation of China (Grant No. 51775564), the 973 program (Grant No. 2014CB046600), and the Fundamental Research Funds for the Central Universities of Central South University (Grant No. 2019zzts946).

Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads

Yong-Cheng Lin^1,2,3, Jia-Yang Chen^1,2, Dao-Guang He^1,2, Xin-He Li^1,3, Jian Yang³

1 School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, People's Republic of China;
2 State Key Laboratory of High Performance Complex Manufacturing, Changsha 410083, People's Republic of China;
3 Light Alloy Research Institute, Central South University, Changsha 410083, People's Republic of China

Received:2019-08-16 Revised:2020-01-02 Online:2020-06-25 Published:2020-06-08
Contact: Yong-Cheng Lin E-mail:yclin@csu.edu.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant No. 51775564), the 973 program (Grant No. 2014CB046600), and the Fundamental Research Funds for the Central Universities of Central South University (Grant No. 2019zzts946).

摘要/Abstract

摘要： Metal sheet spinning is an advanced near-net forming technology for the manufacture of thin-walled ellipsoidal heads. The exact control of dimensional accuracy, however, is a considerable problem for spinning thinwalled parts with large diameter-to-thickness ratios. In this work, a marginal-restraint mandrel-free spinning process with two passes is proposed for the fabrication of thinwalled ellipsoidal heads without wrinkling. A finite element model is established and verified to study the influences of spinning parameters on the dimensional precision of thin-walled ellipsoidal heads. It is found that the spinning parameters considerably influence the deviations of wall thickness and contour characteristics. A small forming angle or small roller fillet radius during the first pass spinning, as well as the small angle between passes or high feed ratio during the second pass spinning, can improve the wall thickness precision. Meanwhile, as the forming angle or feed ratio is increased during the first pass spinning, the contour precision initially increases and then decreases. During the second pass spinning, the contour precision can be improved at a small angle between passes, whereas it deteriorates at a larger roller installation angle. The optimized spinning parameters are obtained and verified by experiments.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00296-0

关键词: Alloy, Thin-walled ellipsoidal heads, Spinning, Finite element model, Dimensional precision

Abstract: Metal sheet spinning is an advanced near-net forming technology for the manufacture of thin-walled ellipsoidal heads. The exact control of dimensional accuracy, however, is a considerable problem for spinning thinwalled parts with large diameter-to-thickness ratios. In this work, a marginal-restraint mandrel-free spinning process with two passes is proposed for the fabrication of thinwalled ellipsoidal heads without wrinkling. A finite element model is established and verified to study the influences of spinning parameters on the dimensional precision of thin-walled ellipsoidal heads. It is found that the spinning parameters considerably influence the deviations of wall thickness and contour characteristics. A small forming angle or small roller fillet radius during the first pass spinning, as well as the small angle between passes or high feed ratio during the second pass spinning, can improve the wall thickness precision. Meanwhile, as the forming angle or feed ratio is increased during the first pass spinning, the contour precision initially increases and then decreases. During the second pass spinning, the contour precision can be improved at a small angle between passes, whereas it deteriorates at a larger roller installation angle. The optimized spinning parameters are obtained and verified by experiments.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00296-0

Key words: Alloy, Thin-walled ellipsoidal heads, Spinning, Finite element model, Dimensional precision

Yong-Cheng Lin, Jia-Yang Chen, Dao-Guang He, Xin-He Li, Jian Yang. Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads[J]. Advances in Manufacturing, 2020, 8(2): 189-203.

参考文献

1. Xia QX, Xiao GF, Long H et al (2014) A review of process advancement of novel metal spinning. Int J Mach Tools Manuf 85:100-121
2. Wong CC, Dean TA, Lin J (2003) A review of spinning, shear forming and flow forming processes. Int J Mach Tool Manuf 43(14):1419-1435
3. Zhang Q, Zhang C, Zhang MJ et al (2015) Research of net-shape power spinning technology for poly-V grooved aluminum pulley. Int J Adv Manuf Technol 81(9/12):1601-1618
4. Lin YC, Wu Q, He DG et al (2020) Effects of solution time and cooling rate on microstructures and mechanical properties of 2219 Al alloy for a larger spun thin-wall ellipsoidal head. J Mater Res Technol. https://doi.org/10.1016/j.jmrt.2020.01.095
5. Lin YC, Qian SS,Chen XMet al (2019)Staggered spinning of thinwalledHastelloy C-276cylindrical parts:numerical simulation and experimental investigation. Thin Wall Struct 140:466-476
6. Xia Q, Long JC, Zhu NY et al (2019) Research on the microstructure evolution of Ni-based superalloy cylindrical parts during hot power spinning. Adv Manuf 7(1):52-63
7. Lin YC, Qian SS, Chen XM et al (2020) Influences of feed rate and wall thickness reduction on the microstructures of thin-walled Hastelloy C-276 cylindrical parts during staggered spinning. Int J Adv Manuf Technol 106(9/10):3809-3821
8. Zhang HR, Zhan M, Guo J et al (2019) Forming the transverse inner rib of a curved generatrix part through power spinning. Adv Manuf 7(1):105-115
9. Huang CQ, Liu JX (2020) Effects of hot spinning and heat treatment on the microstructure, texture, and mechanical properties of A356 wheel hubs. Metall Mater Trans A 51:289-298
10. Saied EK, El-Abden SZ, Abd-Eltwab AA et al (2019) Combining conventional spinning with wall thickness reduction in one pass. Int J Mech Prod Eng Res Dev 9(3):1429-1436
11. Liu CH (2007) Dynamic finite element modeling for the conventional spinning process. J Chin Inst Eng 30(5):911-916
12. Wang L, Long H (2011) Investigation of material deformation in multi-passconventionalmetal spinning.MaterDes32(5):2891-2899
13. Zhan M, Yang H, Zhang JH et al (2007) 3D FEM analysis of influence of roller feed ratio on forming force and quality of cone spinning. J Mater Process Technol 187/188:486-491
14. El-Khabeery MM, Fattouh M, El-sheikh MN et al (1991) On the conventional simple spinning of cylindrical aluminium cups. Int J Mach Tools Manuf 31(2):203-219
15. Xiao Y, Han Z, Fan ZJ et al (2018) A study of asymmetric multipass spinning for angled-flange cylinder. J Mater Process Technol 256:202-215
16. Liu JH, Yang H, Li YQ (2002) A study of the stress and strain distribution of first-pass conventional spinning under different roller-traces. J Mater Process Technol 129(1):326-329
17. Hayama M, Kudo H, Shinokura T (1970) Study of the pass schedule in conventional simple spinning. Bull Jpn Soc Mech Eng 13(65):1358-1365
18. Xia QX, Wang YP, Yuan N et al (2011) Study on spinning of pentagonal cross-section hollow-part based on orthogonal experiment design. Adv Mater Res 314/316:783-788
19. Xia QX, Lai ZY, Long H et al (2013) A study of the spinning force of hollow parts with triangular cross sections. Int J Mach Tools Manuf 68(9/12):2461-2470
20. Kong Q, Yu Z, Zhao Y et al (2017) Theoretical prediction of flange wrinkling in first-pass conventional spinning of hemispherical part. J Mater Process Technol 246:56-68
21. Zhang YQ, Shan DB, Xu WC et al (2010) Study on spinning process of a thin-walled aluminum alloy vessel head with small ratio of thickness to diameter. J Manuf Sci Eng 132(1):014504
22. Xia QX, Shima S, Kotera H et al (2005) Study of the one-path deep drawing spinning of cups. J Mater Process Technol 159(3):397-400
23. Zoghi H, Arezoodar AF, Sayeaftabi M (2012) Effect of feed and roller contact start point on strain and residual stress distribution in dome forming of steel tube by spinning at an elevated temperature. Proc IMechE Part B J Eng Manuf 226:1880-1890
24. Shima S, Kotera H, Murakami H et al (1997) Development of flexible spin-forming method. J Jpn Soc Technol Plastic 38:40-44
25. Rao GJ, Li XH, Zhou L et al (2018) A multi-constraint spinning process of ellipsoidal heads. Int J Adv Manuf Technol 94(1/4):1505-1512
26. Kawai K, Yang LN, Kudo H (2007) A flexible shear spinning of axi-symmetrical shells with a general-purpose mandrel. J Mater Process Technol 192:13-17
27. Kawai K, Yang LN, Kudo H (2001) A flexible shear spinning of truncated conical shells with a general-purpose mandrel. J Mater Process Technol 113(1/3):28-33
28. Kang DC, Gao XC, Meng XF et al (1999) Study on the deformation mode of conventional spinning of plates. J Mater Process Technol 91(1/3):226-230
29. Han ZR, Fan ZJ, Xiao Y et al (2017) A research on thickness distribution of oblique cone in mandrel-free shear spinning. Int J Adv Manuf Technol 90:2901-2912
30. Li Y, Wang J, Lu GD et al (2014) A numerical study of the effects of roller paths on dimensional precision in mandrel-free spinning of sheet metal. J Zhejiang Univ-Sci A 15(6):432-446
31. Sekiguchi A, Arai H (2012) Control of wall thickness distribution by oblique shear spinning methods. J Mater Process Technol 212(4):786-793
32. Polyblank JA, Allwood JM (2015) Parametric toolpath design in metal spinning. CIRP Ann 64(1):301-304
33. Jia Z, Han ZR, Liu BM (2017) Numerical simulation and experimental study on the non-axisymmetric mandrel-free shear spinning. Int J Adv Manuf Technol 92(1/4):497-504
34. Liu CH (2007) The simulation of the multi-pass and die-less spinning process. J Mater Process Technol 192/193:518-524
35. Sugita Y, Arai H (2015) Formability in synchronous multipass spinning using simple pass set. J Mater Process Technol 217:336-344
36. Imamura Y, Ikawa K, Sakane Y et al (2017) Investigation of forming accuracy in mandrel-free hot-spinning. Procedia Eng 207:1701-1706
37. Guo H, Wang J, Lu G et al (2017) A study of multi-pass scheduling methods for die-less spinning. J ZheJiang Univ-Sci A 18(6):413-429
38. User's Manual (2012) ABAQUS analysis user's manual. ABAQUS Inc version 6:12-3
39. Han D, Zhan M, Yang H (2013) Deformation mechanism of TA15 shells in hot shear spinning under various load conditions. Rare Metal Mat Eng 42(2):243-248

[1]	Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding. An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels[J]. Advances in Manufacturing, 2020, 8(2): 160-176.
[2]	Xiang-Ru Chen, Qi-Jie Zhai, Han Dong, Bao-Hua Dai, Hardy Mohrbacher. Molybdenum alloying in cast iron and steel[J]. Advances in Manufacturing, 2020, 8(1): 3-14.
[3]	Tim Outteridge, Nicole Kinsman, Gaetano Ronchi, Hardy Mohrbacher. Editorial: Industrial relevance of molybdenum in China[J]. Advances in Manufacturing, 2020, 8(1): 35-39.
[4]	M. Wasif Safeen, P. Russo Spena, G. Buffa, D. Campanella, A. Masnata, L. Fratini. Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications[J]. Advances in Manufacturing, 2020, 8(1): 59-71.
[5]	Behrouz Bagheri, Mahmoud Abbasi. Development of AZ91/SiC surface composite by FSP: effect of vibration and process parameters on microstructure and mechanical characteristics[J]. Advances in Manufacturing, 2020, 8(1): 82-96.
[6]	Xiao-Liang Shi, Shi-Chao Xiu, Hui-Ling Su. Residual stress model of pre-stressed dry grinding considering coupling of thermal, stress, and phase transformation[J]. Advances in Manufacturing, 2019, 7(4): 401-410.
[7]	Tao Chen, Ye-Xin Chen, Biao Yang, Teng Wang. Effects of boron content on environmental embrittlement of ordered Ni₃Fe alloys[J]. Advances in Manufacturing, 2019, 7(2): 221-227.
[8]	Dong-Dong Chen, Yong-Cheng Lin, Xiao-Min Chen. A strategy to control microstructures of a Ni-based superalloy during hot forging based on particle swarm optimization algorithm[J]. Advances in Manufacturing, 2019, 7(2): 238-247.
[9]	Heng Li, Tian-Jun Bian, Chao Lei, Gao-Wei Zheng, Yu-Fei Wang. Dynamic interplay between dislocations and precipitates in creep aging of an Al-Zn-Mg-Cu alloy[J]. Advances in Manufacturing, 2019, 7(1): 15-29.
[10]	Ze-Xing Su, Chao-Yang Sun, Ming-Wang Fu, Ling-Yun Qian. Physical-based constitutive model considering the microstructure evolution during hot working of AZ80 magnesium alloy[J]. Advances in Manufacturing, 2019, 7(1): 30-41.
[11]	Qin-Xiang Xia, Jin-Chuan Long, Ning-Yuan Zhu, Gang-Feng Xiao. Research on the microstructure evolution of Ni-based superalloy cylindrical parts during hot power spinning[J]. Advances in Manufacturing, 2019, 7(1): 52-63.
[12]	Hong-Rui Zhang, Mei Zhan, Jing Guo, Xian-Xian Wang, Peng-Fei Gao, Fei Ma. Forming the transverse inner rib of a curved generatrix part through power spinning[J]. Advances in Manufacturing, 2019, 7(1): 105-115.
[13]	Ehsan Jafarzadeh, Mohammad R. Movahhedy, Saeed Khodaygan, Mohammad Ghorbani. Prediction of machining chatter in milling based on dynamic FEM simulations of chip formation[J]. Advances in Manufacturing, 2018, 6(3): 334-344.
[14]	Dipesh Popli, Meenu Gupta. Experimental study and optimization of cutting parameters in machining of super alloy with hybrid ultrasonic method[J]. Advances in Manufacturing, 2017, 5(3): 199-216.
[15]	Sergio Manzetti, Francesco Enrichi. State-of-the-art developments in metal and carbon-based semiconducting nanomaterials: applications and functions in spintronics, nanophotonics, and nanomagnetics[J]. Advances in Manufacturing, 2017, 5(2): 105-119.

Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads

Marginal-restraint mandrel-free spinning process for thin-walled ellipsoidal heads

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价