Evaluation on forming process of AZ31 alloy complex curved surfaces by clustering balls spinning method

Hu, Zhiqing; Da, Lijia; Li, Xinchen; Xi, Jia

doi:10.1007/s00170-022-09011-8

Cited by 3 publications

(1 citation statement)

References 18 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

Damage behavior and performance analysis of Al5083 alloy in superplastic bulging

Yi,

Gu,

et al. 2024

Engineering Failure Analysis

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Two-Step Spin Forming of Thin-Walled Heads with Lateral Normal Flanged Holes

Zhu

Huang

et al. 2023

Metals

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A thin-walled head with a lateral normal flanged hole is a key part of a propellant tank, and its low-cost and high-precision forming process is very challenging. In this paper, a two-step method is proposed to preform the head via marginal-restraint mandrel-free spinning and then to realize the flanging of the lateral normal hole using a punching–spinning method. Finite element analysis of round-hole punching–spinning flanging shows that the larger the thinning ratio and the roller fillet radius, the lower the rebound and contour rise amount; the larger the feed ratio, the lower the rebound and the higher the contour rise amount. Further study on the effects of round-hole punching–spinning flanging on the secondary deformation of thin-walled heads shows that the deformation of the head in the area around the flanging hole is less severe than that of the flat blank, and the deformation in the circumferential direction is different from that in the busbar direction. Finally, it is verified through experiments that the two-step method can realize the spin forming of thin-walled heads with lateral normal flanged holes.

show abstract

Evaluation on forming process of AZ31 alloy complex curved surfaces by clustering balls spinning method

Cited by 3 publications

References 18 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

Damage behavior and performance analysis of Al5083 alloy in superplastic bulging

Two-Step Spin Forming of Thin-Walled Heads with Lateral Normal Flanged Holes

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