Comparison of mandrel and counter-roller spinning methods for manufacturing large sheaves

In this paper, a counter-roller spinning method is presented, which is designed to produce relatively thin-walled large sheaves. The large sheave counter-roller spinning force is poorly studied. And the forming forces have a significant influence on industrial applications. Herein, theoretical analysis and numerical simulation methods were utilized to explore the large sheave counter-roller spinning process and spinning force. Anisotropy of the material was considered by the Hill-48 anisotropic yield criterion. Numerical simulation has been demonstrated to correspond to experimental values. The spinning forces in the simulation and experiment matched well and steadily increased throughout the process. The roller and mandrel have similar spinning forces, and the radial spinning force is much larger than other forces. Finally, a theoretical model to compute the spinning force was constructed.

show abstract

“…The groove depth is a fundamental factor in sheaves [7]. The roller radial force was regarded as the spinning force.…”

Section: Groove Depth Influencementioning

confidence: 99%

A Study of Large Sheave Counter-Roller Spinning Force

Zhu

Meng

et al. 2022

J. Phys.: Conf. Ser.

Self Cite

View full text Add to dashboard Cite

show abstract

“…Due to the lack of support from a mandrel, defects such as wrinkles, bulges, and necking are more likely to occur during large-diameter thin-walled tube spinning, which makes it difficult to achieve the expected forming accuracy [23]. Zhu et al [24] studied the distinction of mandrel and counter-roller spinning for large sheaves via conducting a simulation and an experiment. Counter-roller spinning has greater advantages for large sheaves parts.…”

Section: Introductionmentioning

confidence: 99%

Influence of Inner Roller Geometric Parameters on Counter-Roller Spinning with 6061 Aluminum Alloy Tube

Zhao,

Mu,

Zhao

et al. 2023

Metals

View full text Add to dashboard Cite

The inner roller exerts a supportive and thinning effect on the inner side of the tube during counter-roller spinning. In this paper, the Finite Element Analysis (FEA) model of counter-roller spinning for a 6061 aluminum alloy tube was established based on the ABAQUS/Explicit module. The deformation characteristics and the influence of inner roller geometrical parameters on the tube spinning were analyzed. The results showed that the stress–strain on the outer of the tube was greater than that of the inner, and flaring was more prone to occur in the initial stage of counter-roller spinning compared to traditional mandrel spinning. The order of the effects of geometrical parameters of the inner roller on the roundness error and wall thickness deviation was as follows: nose radius > diameter > front angle. The order of factors influencing the inner and outer spinning force was as follows: diameter > nose radius > front angle. Increasing the diameter of the inner roller can improve the spinning stability and forming accuracy of counter-roller spinning. It was beneficial to improve the forming accuracy when the nose radius of the inner roller was slightly larger than that of the outer roller. The front angle of the inner roller has little influence on the spinning forming accuracy.

show abstract

“…Thus, some novel manufacturing technologies, including the counter-roller flow-forming (CRFF)process, were exploited to solve this problem [1]. The CRFF process is a metal-forming method for large cylinder parts with many advantages (e.g., high qualities, material utilization) [2,3].…”

Section: Introductionmentioning

confidence: 99%

The Rollers’ Offset Position Influence on the Counter-Roller Flow-Forming Process

Zhu

Dong

et al. 2022

Metals

Self Cite

View full text Add to dashboard Cite

Background: The general counter-roller flow-forming (CRFF) process rarely considers the roller’s offset position for the symmetric rollers. However, the rollers’ offset position can regulate the tube shape, force, and other features. Studying the novel asymmetric CRFF process, which is the CRFF process with the rollers’ offset position, is essential. Methods: The influence of the rollers’ offset position, the tube blank thickness, thickness reduction on the material deformation, flow-forming force, final tube middle radius, and thickness in the CRFF process are studied using AA5052 aluminum tube experiments and numerical simulation. Result: The final tubes with three tube blank thicknesses, four thickness reduction, and four rollers’ offset positions were obtained by the symmetric and asymmetric CRFF processes. Conclusions: AA5052 aluminum alloy tube can be made by the novel asymmetric CRFF process using a small rollers’ offset position (−17.5–0%). Different rollers’ positions could change the tube’s middle radius. With negative rollers’ offset position, the outer roller force is larger than the inner roller force. The force differences increase with the increase of tube blank thickness, the increase of thickness reduction, and the decrease of rollers’ offset position. The asymmetric CRFF process helps design and construct large tube flow-forming equipment.

show abstract

Comparison of mandrel and counter-roller spinning methods for manufacturing large sheaves

Cited by 9 publications

References 24 publications

A Study of Large Sheave Counter-Roller Spinning Force

A Study of Large Sheave Counter-Roller Spinning Force

Influence of Inner Roller Geometric Parameters on Counter-Roller Spinning with 6061 Aluminum Alloy Tube

The Rollers’ Offset Position Influence on the Counter-Roller Flow-Forming Process

Contact Info

Product

Resources

About