Cryogenic die-less spinning of aluminum alloy thin-walled curved components and microstructure evolution

Huang, Ke; Yi, Youping; Huang, Shiquan; He, Hailin; Dong, Fei; Jia, Yanzhen; Yu, Wenwen

doi:10.1016/j.jmapro.2023.02.045

Cited by 12 publications

(3 citation statements)

References 27 publications

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“…This kind of special-shaped storage tank dome is extremely difficult to manufacture integrally [5,6]. Among the dome processing methods, the integral spinning process offers significant advantages in forming such large, thin-walled dome components [7][8][9][10][11][12][13]. Specifically, compared with the method of welding after piece-by-piece manufacturing, the spinning process reduces the formation of weld seams and provides increased reliability for the storage tank domes, along with a cost-effective cost and forming accuracy.…”

Section: Introductionmentioning

confidence: 99%

A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes

Zhu

Huang

et al. 2023

Metals

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The special-shaped tank dome of a launch vehicle is a large, thin-walled, curved structure that is difficult to form using the conventional center-restraint spinning method. This study proposes a two-step marginal-restraint mandrel-free spinning method for forming large domes. The finite element analysis results indicate that a larger roller fillet radius and larger feed ratios lead to a larger upper convex angle and the minimum thickness value for the bottom contour. This study explored the impact of shape parameter variations on the upper convexity and transition rounding angle on forming accuracy. The results show that the convexity of the bottom of the special-shaped domes increases with a larger roller fillet radius and larger feed ratios while the overall height decreases. The forming accuracy is adversely affected by larger transition rounding angles and smaller upper convexities. For the accurate forming of domes, the mutual coupling influence during two-step forming should be considered, and a suitable process and suitable trajectory compensation parameters must be carefully selected. Finally, the study verified that a two-step marginal-restraint mandrel-free spinning method with a 10 mm roller fillet radius, a 2 mm/r feed ratio, and the corresponding trajectory compensation can achieve the precise forming of 2250 mm thin-walled special-shaped domes.

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Section: Introductionmentioning

confidence: 99%

A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes

Zhu

Huang

et al. 2023

Metals

View full text Add to dashboard Cite

show abstract

“…The use of one-step spinning to form the top cover helps reduce costs and avoid accuracy losses caused by secondary clamping. The costs can be further reduced by using mandrel-free spinning [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Process Parameters Optimization of One-Step Spin Forming of Top Cover with Center Flanged Hole

Zhu,

Huang,

et al. 2023

Metals

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To assist the low-cost manufacturing of tanks, a one-step method of marginal-restraint mandrel-free spin forming is therefore proposed in this study for the forming of top covers with flanged holes. With the finite element simulation analysis, three different forming strategies are discussed, and the best spinning process is identified. The proposed forming strategies involve preforming the flanged surface first and then preforming the spherical and flanged surfaces in a subsequent trajectory and is proved to have better forming accuracy. Furthermore, the forming quality of the spun parts is improved and optimized by employing more passes, smaller feed ratios, and larger roller fillet radii. It was experimentally verified that the marginal-restraint mandrel-free spinning one-step method with five passes, a feed ratio of 1 mm/r, and a roller fillet radius of 60 mm for the cylindrical roller can achieve accurate forming of a top cover with a center flange hole.

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“…In aviation and aerospace industries, aluminum alloy is a widely used metal material. Among the 7 series aluminum alloys, 7075 aluminum alloy has superior tensile strength, good mechanical properties and excellent corrosion resistance [1],2]. However, due to the material's high plasticity, easy deformation and other characteristics, it is difficult to guarantee the surface quality and accuracy after machining with ordinary deep hole turning methods [3] , which seriously hinders the further development of aviation and other related technical equipmentError!…”

Section: Introductionmentioning

confidence: 99%

Study on surface Morphology of 7075 aluminum alloy deep hole by two-dimensional ultrasonic elliptical vibration Boring

Ye¹,

Tong

Hu³

et al. 2023

Preprint

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The study focused on the use of two-dimensional ultrasonic elliptical vibration boring (2D-UEVB) to improve the surface quality of deep hole tube parts made from 7075 aluminum alloy. The tool tip trajectory model and the surface roughness model of 2D-UEVB deep hole were established. It was found that 2D-UEVB could obtain lower surface roughness than common boring (CB) through analyzing the theoretical model. Finally, the effects of boring parameters and acoustic parameters on surface morphology were studied throughsingle factor test and four-factor four-level orthogonal test. After the 2D-UEVB, the surface roughness Ra value decreased in different degreesaccording to the experimental results. However, the reduction of Ra was affected differently by the various acoustic parameters and boring parameters. With the increase of feed rate, the surface roughness Ra shows a significant increasing trend. With the increase of spindle speed, the surface roughness Ra shows a trend of decreasing first and then increasing. The Ra displayed a continuous decreasing trend with the ultrasonic amplitude increased. The influence of cutting depth on the roughness is not significant. The results demonstrated that better surface texture and surface quality can be obtained with lower feed rate, medium spindle speed and larger ultrasonic amplitude in two-dimensional ultrasonic vibration boring.

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Cryogenic die-less spinning of aluminum alloy thin-walled curved components and microstructure evolution

Cited by 12 publications

References 27 publications

A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes

A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes

Process Parameters Optimization of One-Step Spin Forming of Top Cover with Center Flanged Hole

Study on surface Morphology of 7075 aluminum alloy deep hole by two-dimensional ultrasonic elliptical vibration Boring

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