Effect of blank quenching on shear spinning forming precision of 2219 aluminum alloy complex thin-walled components

Li, Zhixin; Zhan, Mei; Fan, Xiaoguang; Dong, Yunda; Xu, Luopeng

doi:10.1016/j.cja.2022.11.027

Cited by 9 publications

(2 citation statements)

References 21 publications

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“…According to the restraint position, the process of mandrel-free spinning to create domes involves two main restraint setup methods: center-restraint mandrel-free spinning and marginal-restraint mandrel-free spinning. As shown in Figure 2, center-restraint mandrel-free spinning is a method that adopts pre-forming with a "press drum" and then completes the dome spinning through the combined interaction of a forming roller and a pressure roller on the prefabricated blanks [24]. Compared with the molded spinning method, the mandrel-free spinning replaces the large core mold by forming rollers, and it simplifies the tooling.…”

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

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show abstract

“…For top covers with flanged holes and multiple reverse-curvature bus features, such as that shown in Figure 1, multi-step forming with different processes is still generally adopted. Zhang used a molded spinning method to form domes [3] and explored the instability mechanisms [4,5] in the molded spinning process and the influence of different process parameters such as the feed ratio and roller fillet radius on the forming quality [6][7][8]. The domes and top covers were successfully developed experimentally to meet the forming quality requirements [9,10].…”

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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On the Relevance of Modeling Options in ABAQUS Regarding the Spinning Process Simulation

Korolakina,

Bouchard,

Mocellin

et al. 2023

Lecture Notes in Mechanical Engineering

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Effect of blank quenching on shear spinning forming precision of 2219 aluminum alloy complex thin-walled components

Cited by 9 publications

References 21 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

On the Relevance of Modeling Options in ABAQUS Regarding the Spinning Process Simulation

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