Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

doi:10.1007/s11465-019-0528-z

Front. Mech. Eng.

2019, Vol. 14

Issue (3) : 351-357 https://doi.org/10.1007/s11465-019-0528-z

RESEARCH ARTICLE

Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

Dawei ZHANG(

), Fan LI, Shuaipeng LI, Shengdun ZHAO

School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China

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Abstract

Counter-roller spinning (CRS), where the mandrel is replaced by rollers, is an effective means of manufacturing large-sized, thin-walled, cylindrical parts with more than 2500 mm diameter. CRS is very complex because of multi-axis rotation, multi-local loading along the circumference, and radial-axial compound deformation. Analytical or experimental methods cannot fully understand CRS. Meanwhile, numerical simulation is an adequate approach to investigate CRS with comprehensive understanding and a low cost. Thus, a finite element (FE) model of CRS was developed with the FORGE code via meshing technology, material modeling, determining the friction condition, and so on. The local fine mesh moving with the roller is one of highlights of the model. The developed 3D-FE model was validated through a CRS experiment by using a tubular blank with a 720 mm outer diameter. The developed 3D-FE model of CRS can provide a basis for parameter optimization, process control, die design, and so on. The data on force and energy predicted by the 3D-FE model can offer reasonable suggestions for determining the main mechanical parameters of CRS machines and selecting the motors. With the predicted data, an all-electric servo-drive system/machine with distributed power was designed in this work for CRS with four pairs of rollers to manufacture a large-sized, thin-walled, cylindrical part with 6000 mm diameter.

Keywords large-sized cylindrical part counter-roller spinning aluminum alloy finite element method distributed power

Corresponding Author(s): Dawei ZHANG

Just Accepted Date: 20 November 2018 Online First Date: 21 December 2018 Issue Date: 24 July 2019

Cite this article:

Dawei ZHANG,Fan LI,Shuaipeng LI, et al. Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts[J]. Front. Mech. Eng., 2019, 14(3): 351-357.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0528-z
https://academic.hep.com.cn/fme/EN/Y2019/V14/I3/351

Fig.1 Sketch of counter-roller spinning

Tab.1 Main parameters of aluminum alloy 5052

Fig.2 FE model of the CRS process (backward spinning process with four pairs of rollers): (a) Assembly relations of geometry models and (b) local fine mesh of the tubular blank/workpiece

Fig.3 Shape of the compressed ring of aluminum alloy 5052: (a) Lubricated condition and (b) dry friction

Fig.4 CRS process with two pairs of rollers: (a) 3D-FE model, (b) spinning experiment, and (c) structure of the roller (unit: mm)

Tab.2 Main parameters in the counter-roller spinning experiment

Fig.5 Shape of the cylindrical part after spinning: (a) Experimental result and (b) numerical result

Fig.6 Distribution of wall thickness

Fig.7 Distribution of field variables: (a) Effective stress and (b) effective strain

Fig.8 Force and torque of counter-roller spinning for a 6 m aluminum alloy cylindrical part: (a) Spinning force of the roller and (b) torque of the turntable

Fig.9 3D model of the vertical counter-roller spinning machine

Fig.10 Rotation mechanism of the tubular blank/workpiece: (a) Overall layout, (b) one double-geared-roll appliance, and (c) double-geared roll

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