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Forming dependence on spin roller paths for thin-walled complex components from 2195 Al-Li alloy TWBs

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Abstract

The spin forming provides an approach to manufacturing large-diameter thin-walled complex curved surface components based on tailor-welded blanks produced from small 2195 Al-Li alloy plates, even scraps by friction stir welding (FSW). In this study, three spin forming schemes of single-pass, two-pass, and three-pass roller paths are designed. The corresponding experimental results indicate that the rolling of the rollers during spin forming is helpful in reducing the wall thickness inhomogeneity between weld and parent material and hence improves the surface roughness. Meanwhile, spin forming makes the welds deflect. With the increase of spinning passes, the forming height, open diameter, and the weld deflection angle of components increase. Additionally, the wall thickness difference, the surface quality, and the overall unfitability of components are all improved to some extent. However, there still exists insufficient forming height and over large open diameter due to the unfitability. Therefore, to obtain an ideal formed component, a spin forming scheme was proposed through increasing spinning passes in the ellipsoidal and cylindrical segments of the mandrel. Using this improved scheme, the forming height was increased with the maximum of 18%, the unfitability value was decreased with the maximum of 97%, the surface quality was significantly improved, and the ideal spun component was obtained.

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Funding

This work was supported by the National Science Fund for Distinguished Young Scholars of China (Project 51625505), the National Key R&D Program of China (Project 2020YFA0711100), the National Natural Science Foundation of China (Project 91860130, Project U1937203 and Project U1910213), and the Natural Science Basic Research Plan in Shaanxi Province of China (No. 2020JQ-166).

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Authors and Affiliations

  1. Shaanxi Key Laboratory of High Performance Precision Forming Technology and Equipment, School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Hongrui Zhang, Mei Zhan, Zebang Zheng, Rui Li, Xiaolei Cui, Shuwan Chen & Yudong Lei

  2. Key Laboratory of High Performance Manufacturing for Aero Engine (Ministry of Industry and Information Technology), School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Hongrui Zhang & Zebang Zheng

  3. State Key Laboratory of Solidification Processing, School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Hongrui Zhang, Mei Zhan, Zebang Zheng, Rui Li, Xiaolei Cui, Shuwan Chen & Yudong Lei

  4. Sichuan Aerospace Long March Equipment Manufacturing Co., Ltd, Chengdu, 610100, China

    Fei Ma

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  1. Hongrui Zhang
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  2. Mei Zhan
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  3. Zebang Zheng
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  4. Rui Li
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  5. Fei Ma
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  6. Xiaolei Cui
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  7. Shuwan Chen
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  8. Yudong Lei
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Contributions

HZ: conceptualization, investigation, software, methodology, experiments, formal analysis, writing — original draft. MZ: writing — review and editing, project administration, funding acquisition. ZZ: conceptualization, supervision, resources, writing — review and editing. RL: software. FM: data curation. XC: investigation. SC: data curation. YL: experiments.

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Correspondence to Mei Zhan or Zebang Zheng.

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Zhang, H., Zhan, M., Zheng, Z. et al. Forming dependence on spin roller paths for thin-walled complex components from 2195 Al-Li alloy TWBs. Int J Adv Manuf Technol 120, 3113–3122 (2022). https://doi.org/10.1007/s00170-022-08974-y

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  • DOI: https://doi.org/10.1007/s00170-022-08974-y

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