Friction between the tube and spinning tools is one of the main factors that affected the uneven deformation in hot power backward spinning process of a high-strength casting aluminum alloy tube, which has a significant and complicated influence on the onset of the ellipticity in the process. To study the effect of the friction on the ellipticity, a 3D coupled thermo-mechanical FE model of the process was built based on ABAQUS/Explicit code and validated by experiment. Then, the influence law and the mechanism of friction between the spinning tools and tube on ellipticity of the tube during the process were studied. The results show that the ellipticity increases gradually with the increase of the friction between the roller, mandrel, and tube, while the effects of them on the ellipticity are relatively small in the first three passes. In pass 1, the ellipticity deceases progressively with the increase of the friction between the unloading ring and tube, and it increases slightly in passes 2, 3, and 4. In addition, the optimal combinations of the friction coefficient for each pass in the process were obtained based on the intuitive analysis of orthogonal experiment. Then, the selection principle of the friction coefficients was proposed to control the ellipticity of the process. The achievements of this study can provide a guideline for determining the friction coefficient between the spinning tools and tube during hot power backward spinning process of the high-strength casting aluminum alloy tube.
High-strength casting aluminum alloy Tube Hot power backward spinning Friction Ellipticity
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The authors would like to thank the National Natural Science Foundation of China (Nos. 51165037 and 51665041), the State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology (No.P2014-08) for the support given to this research.