Forming quality optimization of 2219 aluminum alloy thin-walled complex components based on fracture constraint in spin forming

Small module tooth-shaped parts (SMTSPs) with characteristics of hollow, thin wall-thickness made of difficult-to-deformed metals, are one of the most precision transmission components, which are traditionally manufactured by tooth hobbing or tooth shaping. Current-assisted splitting spinning (CASS) has been introduced as a method to achieve integrated manufacturing of SMTSPs. A coupled electrical-thermal-mechanical finite element analysis (FEA) model was established based on the ABAQUS software, the deformation characteristics of the small module tooth and the mechanism of tooth filling under current-assisted splitting spinning were investigated. A BP neural network (BPNN) was used to establish the mapping relationship between process parameters of CASS and forming quality evaluation metrics, and the Non-dominated Sorting Genetic Algorithm (NSGA-II) multi-objective genetic optimization algorithm was employed to optimize the forming process parameters. The results show that the material at the tooth tip along the radial direction is in the state of tensile stress along radial and compressive stresses along tangential and axial directions, which promotes the radial flowing of the material and is beneficial the tooth filling of SMTSPs; the tooth saturation increases obviously under pulse current comparing without pulse current; the BPNN combined with the NSGA-II algorithm can reliably optimize the process parameters of the CASS, improving the forming quality of SMTSPs; experiments verified the feasibility of the process and the accuracy of the predictive model based on the optimization results.

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Damage evolution mechanism of aluminum alloy stiffened cylinders during flow forming

Meng,

Yu,

Wang

2024

Preprint

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Fracture is one of typical defects for complex stiffened cylinders during flow forming. The introduction of complex structures makes fracture prediction challenging. This study aims to assess the forming limits of stiffened cylinders during flow forming, alongside the selection of appropriate prediction models. Therefore, a spinnability method was proposed to evaluate the formability of stiffened cylinders and its corresponding finite element model was developed. The results show that cracks initiated at the stiffener downstream fillet in flow forming of AA6061-T6 stiffener cylinders, and then developed along the circumferential direction due to significant axial tensile stresses. Four typical uncoupled damage models were incorporated into the finite element model to simulate the damage evolution in spinnability tests of stiffened cylinders. The prediction results show that all selected models demonstrated an ability to correctly predict the location of cracking, but H-C model offers the most accurate predictions in spinnability tests of AA 6061-T6 stiffened cylinders. These approaches can provide an evaluation method for flow spinning process design of stiffened cylinders.

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Forming quality optimization of 2219 aluminum alloy thin-walled complex components based on fracture constraint in spin forming

Cited by 4 publications

References 24 publications

An overview of strategies for identifying manufacturing process window through design of experiments and machine learning techniques while considering the uncertainty associated with

An overview of strategies for identifying manufacturing process window through design of experiments and machine learning techniques while considering the uncertainty associated with

Multi-objective optimization of current-assisted splitting spinning of small module tooth-shaped part based on the combination of BP neural network and NSGA-II algorithm

Damage evolution mechanism of aluminum alloy stiffened cylinders during flow forming

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