In this paper, based on MSC Simufact.Forming v16.0 simulation software, the process parameters in the multi-pass spinning production of deep cylinders with a large diameter–thickness ratio are optimized, and the ten-pass spinning process of a deep cylinder with a diameter of 500 mm, thickness of 2 mm and depth of 700 mm is realized. By controlling the four process parameters of mandrel speed, feed rate, spinning wheel fillet radius and spinning wheel angle of attack, the influence of the four process parameters on the spinning force and the wall thickness deviation of the formed workpiece is studied. The results show that the radial spinning force and tangential spinning force are at their minimum when the mandrel speed, feed rate, spinning wheel fillet radius and spinning wheel angle of attack are 500 rpm, 1 mm/rev, 6 mm and 35°, respectively. At these setup conditions, the spinning efficiency is the highest and the workpiece is not prone to defects. The wall thickness deviation of the workpiece will decrease with the increase in the mandrel speed; with the increase in the feed rate, the radius of the round corner and spinning wheel angle of attack, the wall thickness deviation increases first and then decreases.

This paper describes the effect of pass ratio on the forming quality of magnesium-aluminum composite pipes formed by multi-pass spinning. Established by NX software, the finite element simulation model of 7075 aluminum alloy-ZM21 magnesium alloy composite pipes was imported into Simufact. Forming software for simulation analysis. Based on previous research, the appropriate spinning parameters were selected. When the total reduction is constant, the ratios of three different reductions are studied and the final stress-strain results are obtained by finite element software simulation. By analyzing the straightness, cylindricity, and wall thickness of magnesium-aluminum composite pipes, the influence law of different pass reduction ratios on the surface quality of composite pipes is obtained. By analyzing the stress distribution of the magnesium-aluminum composite pipes interface, the influence law of different pass reduction ratios on the interface bonding strength of composite pipes is obtained. The final results show that compared with the initial pass, the contact stress on the surface of the magnesium-aluminum pipes in the subsequent pass is much greater than that in the initial pass. In the subsequent passes, the contact stress of the final pass has little difference. When the final pass reduction decreases, the cylindricity and straightness of the composite pipes decrease, so the surface quality of the composite pipes depends on the final pass reduction. Therefore, in the actual production process, the intermediate pass reduction can be increased and the final pass reduction can be appropriately reduced. These results provide technical guidance for the selection and optimization design of the reduction ratio of multipass spinning of magnesium-aluminum bimetallic composite pipes.

The conical rotary part with variable wall thickness is a typical aircraft engine sheet metal casing, which requires high forming quality. In this paper, the hot power spinning process of conical rotary part with continuously variable wall thickness of superalloy GH4169 was simulated by DEFORM-3D FE (finite element) software. The equivalent stress, equivalent strain and temperature distribution characteristics were analysed to explore the forming mechanism. The single factor variable method was used to explore the influence of three process parameters, namely, the mandrel speed, the roller feed ratio and the spinning temperature, on the forming quality. The wall thickness deviation and the roundness error of the cone outer surface were taken as the evaluation indexes. Excessive thinning rate will produce large equivalent strain, which may lead to work piece fracture. Therefore, appropriate roller feed ratio should be selected to reduce the generation of defects. The results provide a theoretical basis for improving the service life of aero-engine sheet metal casing.