Abstract
The initial blank employed to form aluminum alloy thin-walled special head was cut in metal strip, which has the unavoidable fluctuation of blank thickness, i.e., blank flatness (BF) because of the rolling technology. The BF increases the uncertainty of forming process and causes difference in the forming quality. In this paper, to research the influence of BF on forming quality, different BF types are defined as edge-down, edge-up, edge-w, and ideal blank flatness, and the different BF values are ± 0.5 mm and ± 1.0 mm got by experimental measurement. And three-dimensional finite element (FE) spinning models considering BF were established. Different BF types are achieved by assigning discrete ordinates to nodes using Latin hypercube sampling. Models are verified by theoretical methods. Further, influence of BF on spinning force (F), degree of inhomogeneous deformation (φ), and thickness of head (T) is investigated. The results show that the BF has different influence on F in the earlier, middle, and later stage of spinning. φ of BF of edge-down is largest; φ caused by BF = ± 0.5 mm is less than that caused by BF = ± 1.0 mm. BF type and value of the metal blank have no significant influence on T. In conclusion, the BF of the circular blank required by the spinning head should be typed in edge-w, and the value should be less than ± 1.0 mm. The research offers an in-depth understanding of the effects of BF on the forming quality in the head spinning process and thus lays a basis for choosing the initial blank.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Music O, Allwood JM, Kawai K (2010) A review of the mechanics of metal spinning. J Mater Process Technol 210(1):3–23
Liu JH, Yang H, Li YQ (2002) A study of the stress and strain distributions of first-pass conventional spinning under different roller traces. J Mater Process Technol 129(1):326–329
Wang L, Long H (2011) A study of effects of roller path profiles on tool forces and part wall thickness variation in conventional metal spinning. J Mater Process Technol 211(12):2140–2151
Zhan M, Yang H, Zhang JH (2006) Research on variation of stress and strain field and wall thickness during cone spinning. Mater Sci Forum 532-533(6):149–152
Fu MW, Yong MS, Muramatsu T (2008) Die fatigue life design and assessment via CAE simulation. Int J Adv Manuf Technol 35(9–10):843–851
Huang L, Yang H, Zhan M (2008) 3D-FE modeling method of splitting spinning. Comput Mater Sci 42(4):643–652
Zhang JH, Zhan M, Yang H, Jiang ZQ, Han D (2012) 3D-FE modeling for power spinning of large ellipsoidal heads with variable thicknesses. Comput Mater Sci 53:303–313
Wu WL, Wang WC, Wei L (2018) The study of improving the strip flatness in run-out-table during laminar cooling. Int J Adv Manuf Technol 95:4419–4437
Wang QL, Sun J, Liu YM et al (2017) Analysis of symmetrical flatness actuator efficiencies for UCM cold rolling mill by 3D elastic–plastic FEM. Int J Adv Manuf Technol 92(10):1–19
Kitayama S, Natsume S, Yamazaki K, Han J, Uchida H (2016) Numerical optimization of blank shape considering flatness and variable blank holder force for cylindrical cup deep drawing. Int J Adv Manuf Technol 85(9–12):2389–2400
Cho S, Kim J-Y (2012) Straightness and flatness evaluation using data envelopment analysis. Int J Adv Manuf Technol 63(5–8):731–740
Sebastiani G, Brosius A, Ewers R, Kleiner M, Klimmek C (2006) Numerical investigation on dynamic effects during sheet metal spinning by explicit finite-element-analysis. J Mater Process Technol 177(1–3):401–403
Wang L, Long H (2011) Investigation of material deformation in multi-pass conventional metal spinning. Mater Des 32(5):2891–2899
Kleiner M, Göbel R, Kantz H, Ch K, Homberg W (2002) Combined methods for the prediction of dynamic instabilities in sheet metal spinning. CIRP Ann 51(1):209–214
Shan DB, Xu WC, Lv Y (2010) Study on spinning process of a thin-walled aluminum alloy vessel head with small ratio of thickness to diameter. J Manuf Sci Eng 132(1):014504 1–4
Özer A, Sekiguchi A, Arai H (2012) Experimental implementation and analysis of robotic metal spinning with enhanced trajectory tracking algorithms. Robot Comput Integr Manuf 28(4):539–550
Abdelkhalek S, Montmitonnet P, Legrand N, Buessler P (2011) Coupled approach for flatness prediction in cold rolling of thin strip. Int J Mech Sci 53:661–675
Cui XL, Zhan M, Gao PF, Ma F, Guo J, Li R, Li ZX, Zhang HR (2018) Influence of blank thickness fluctuation on flange state and final thickness distribution in the power spinning of thin-walled head. Int J Adv Manuf Technol 99:363–337
Shi F, Long H, Zhan M et al (2014) Uncertainty analysis on process responses of conventional spinning using finite element method. Struct Multidiscip Optim 49(5):839–850
Gao PF, Li XD, Yang H, Fan XG, Lei ZN (2016) Influence of die parameters on the deformation inhomogeneity of transitional region during local loading forming of Ti-alloy rib-web component. Int J Adv Manuf Technol 90:2109–2119
Funding
The authors would like to acknowledge the support from the National Science Fund for Distinguished Young Scholars of China (Project 51625505), Key Program Project of the Joint Fund of Astronomy, and National Natural Science Foundation of China (Project U1537203).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Cui, X.L., Zhan, M., Gao, P.F. et al. Influence of blank flatness on the forming characteristics in the spinning of aluminum alloy thin-walled special head. Int J Adv Manuf Technol 107, 3259–3266 (2020). https://doi.org/10.1007/s00170-020-05166-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-020-05166-4