Spinning deformation mechanism of aluminum alloy cylinder with multi-level stiffeners based on numerical simulation

Meng, Yu; Yu, Xiaokang; Lai, Zheyuan; Zhao, Yixi; Yu, Zhongqi

doi:10.1088/1757-899x/1270/1/012038

Cited by 2 publications

(1 citation statement)

References 10 publications

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“…The spinning of domes can be performed using either molded spinning or mandrelfree spinning. As shown in Figure 1, molded spinning involves clamping the workpiece on a core mold with the tail at the top, rotating it together with the machine tool spindle, and pressing the roller onto the material to produce plastic flow, and the curved domes are finally formed with the movement of the roller feed [14][15][16]. When using molded spinning for the processing of the domes of a rocket fuel tank-which is a large, thinwalled dome part with a high diameter-thickness ratio and weak rigidity-equal thickness, uncoordinated deformation always occurs during the core molded spinning.…”

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

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

Spinning deformation mechanism of aluminum alloy cylinder with multi-level stiffeners based on numerical simulation

Cited by 2 publications

References 10 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

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

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