Research on die-less spinning of square section cone by ball-crown-shape roller

Zhou, Shuyang; Han, Zhiren; Zhang, Jia; Liu, Baoming; Gong, Xue

doi:10.1007/s00170-022-09479-4

Cited by 4 publications

(1 citation statement)

References 17 publications

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“…This leads to destabilization phenomena, such as wrinkling, cracking, non-adhesive films, surface rippling, and bonding defects, all of which can seriously affect the processing accuracy of the storage tank. Wrinkling is one of the main forming defects of thin plates, and it is caused by compression instability [17][18][19] during cracking when the material deformation exceeds the tensile limit of the metal [20,21]. Non-adherence to the mold is caused by elastic recovery after unloading of the roller, especially for large-diameter thin-walled domes.…”

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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