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

doi:10.1007/s40436-020-00296-0

Abstract

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.

TrendMD

References

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]	Angela Cusanno, Pasquale Guglielmi, Donato Sorgente, Gianfranco Palumbo. Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part [J]. Advances in Manufacturing, 2025, 13(2): 284-302.
[2]	Xin Wang, Qing-Liao He, Biao Zhao, Wen-Feng Ding, Qi Liu, Dong-Dong Xu. Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys [J]. Advances in Manufacturing, 2025, 13(1): 155-166.
[3]	Qiang-Qiang Zhai, Zhao Liu, Ping Zhu. Understanding microstructure-property relationships of HPDC Al-Si alloy based on machine learning and crystal plasticity simulation [J]. Advances in Manufacturing, 2024, 12(3): 497-511.
[4]	Yuan-Zhe Hu, Ru-Xue Liu, Jia-Peng He, Guo-Wei Zhou, Da-Yong Li. Deep learning methods for roping defect analysis in aluminum alloy sheets: prediction and grading [J]. Advances in Manufacturing, 2024, 12(3): 576-590.
[5]	Shailendra Chauhan, Rajeev Trehan, Ravi Pratap Singh. State of the art in finite element approaches for milling process: a review [J]. Advances in Manufacturing, 2023, 11(4): 708-751.
[6]	Qing-An Yin, Zhan-Qiang Liu, Bing Wang. Prediction of temperature field in machined workpiece surface during the cutting of Inconel 718 coated with surface-active media [J]. Advances in Manufacturing, 2023, 11(3): 378-389.
[7]	Liang-Liang Xia, Shi-Hong Zhang, Yong Xu, Shuai-Feng Chen, Boris B. Khina, Artur I. Pokrovsky. Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis [J]. Advances in Manufacturing, 2023, 11(2): 311-328.
[8]	G. V. Jagadeesh, Srinivasu Gangi Setti. Surface integrity of ball burnished bioresorbable magnesium alloy [J]. Advances in Manufacturing, 2023, 11(2): 342-362.
[9]	Ben-Kai Li, Biao Zhao, Wen-Feng Ding, Yu-Can Fu, Chang-He Li, Rong Wang, Yan-Jun Zhao. CBN grain wear and its effects on material removal during grinding of FGH96 powder metallurgy superalloy [J]. Advances in Manufacturing, 2023, 11(1): 21-38.
[10]	Bao-Yu Zhang, Yu-Ning Zeng, Xue-Qin Pang, Song-Qing Li, Xiao Liu, Wen-Jun Deng. Feasibility analysis and process characteristics of selective laser ablation assisted milling Inconel 718 [J]. Advances in Manufacturing, 2022, 10(4): 495-519.
[11]	Qi-Dong Sun, Jie Sun, Kai Guo, Saad Waqar, Jiang-Wei Liu, Lei-Shuo Wang. Influences of processing parameters and heat treatment on microstructure and mechanical behavior of Ti-6Al-4V fabricated using selective laser melting [J]. Advances in Manufacturing, 2022, 10(4): 520-540.
[12]	Tian-Jun Bian, Heng Li, Chao Lei, Chang-Hui Wu, Li-Wen Zhang. Microstructures and properties evolution of Al-Zn-Mg-Cu alloy under electrical pulse assisted creep aging [J]. Advances in Manufacturing, 2022, 10(4): 596-609.
[13]	Prveen Bidare, Amaia Jiménez, Hany Hassanin, Khamis Essa. Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: a review [J]. Advances in Manufacturing, 2022, 10(2): 175-204.
[14]	Kai Ding, Yuan-Heng Zhang, Shang-Fei Qiao, Guan-Zhi Wu, Tao Wei, Xia Liu, Yu-Lai Gao. Formation of the anomalous microstructure in the weld metal of Co-based alloy/AISI 410 stainless steel dissimilar welded joint [J]. Advances in Manufacturing, 2022, 10(2): 250-259.
[15]	Muhammad Rizwan Awan, Hernán A. González Rojas, José I. Perat Benavides, Saqib Hameed. Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs [J]. Advances in Manufacturing, 2022, 10(2): 260-271.