Study of dieless radial spinning for thick-walled cylindrical parts with external grooves

Abstract

Thick-walled cylindrical parts with external grooves are common components in the automobile and aviation fields. Such components can be produced by pressing the outer surface of a spinning thick-walled aluminum alloy tube by the dieless radial spinning process. The forming characteristics in the spinning process and the effects of various process parameters on forming were studied by using orthogonal tests and finite element simulations. During the forming process, bulge and thickness reductions occur because of material flow. The results of an investigation of process parameter effects show that the stress yield ratio (ξ) had no significant effect on forming. However, the feed thickness ratio (η) and initial wall thickness of the tube (t0) crucially affected the forming quality (e.g., the heights of bulges and thickness reduction in the groove area). Thick-walled tubes presented different phenomena compared to the thin-walled. Keywords Thick-walled; dieless; spinning; orthogonal test; finite element; aluminum alloy Highlights of the research:1. The thick-walled cylindrical parts with external grooves were produced by the dieless radial spinning process.2. The effects of the process parameters on the forming quality were analyzed.3. The difference between the thick-walled tubes thin-walled tubes while spinning process was revealed. 4. A suggestion about the values of the parameters to obtain an eligible part were given.

Numerical simulation and experimental study on non-axisymmetric spinning with a groove at the middle of the tube

“…Three spinning methods were contrasted in their study to control thickness distribution and suppress the wrinkling defect. Liu et al [17] produced the thick-wall cylindrical part with external grooves using double rollers. Kwiatkowski et al [18] compared different roller trajectories for spinning necking tube without any mandrel and concluded that the value of inclined area as well as the elongation of the part highly depend on the roller path.…”