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Influence of blank thickness fluctuation on flange state and final thickness distribution in the power spinning of thin-walled head

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Abstract

The initial blank exists unavoidable thickness fluctuation. In the spinning process of head parts, this fluctuation affects the flange state and final wall thickness distribution of the parts, which seriously deteriorates the forming quality. To research the blank thickness fluctuation on flange and spun head thickness distribution, three-dimensional (3D) finite element (FE) models considering blank fluctuation for the spinning process of 2219 aluminum head parts were established. The blank fluctuation was characterized using the Latin hypercube sampling method (LHS), and three fluctuation ranges and three fluctuation types were adopted (type 1, the average blank wall thickness is approximately equal to 1.0 mm, 1.0 mm is defined as the ideal standard blank thickness (ST); type 2, the average blank wall thickness is bigger than ST; type 3, the average blank wall thickness is smaller than ST). Then, flange fluctuations and the variations of wall thickness deviation were analyzed. The results showed that the maximum flange fluctuation appears within the 20% spinning process; the maximum flange fluctuation of type 1 is larger than those of type 2 and type 3. In the top zone of the spun head, the maximum wall thickness deviation of type 3 is the largest. While in the middle and edge zones, the maximum wall thickness deviation of type 2 is the largest. Simultaneously, a greater initial blank fluctuation leads to the bigger thickness frequency deviation. The research provides an in-depth understanding of the effects of blank wall thickness fluctuation on the forming quality in the head spinning process, and thus lays a basis for choosing the blank.

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Funding

This study is financially supported by 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), and the Research Fund of the State Key Laboratory of Solidification Processing (Projects 118-TZ-2015).

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Authors and Affiliations

  1. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, 710072, China

    X. L. Cui, M. Zhan, P. F. Gao, J. Guo, R. Li, Z. X. Li & H. R. Zhang

  2. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    X. L. Cui, M. Zhan, P. F. Gao, J. Guo, R. Li, Z. X. Li & H. R. Zhang

  3. Long March Machinery Factory, China Aerospace Science and Technology Corporation, Chengdu, 610100, China

    F. Ma

Authors
  1. X. L. Cui
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  2. M. Zhan
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  3. P. F. Gao
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  4. F. Ma
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  5. J. Guo
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  6. R. Li
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  7. Z. X. Li
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  8. H. R. Zhang
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Correspondence to M. Zhan.

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Cui, X.L., Zhan, M., Gao, P.F. et al. 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, 363–372 (2018). https://doi.org/10.1007/s00170-018-2486-8

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  • DOI: https://doi.org/10.1007/s00170-018-2486-8

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