Skip to main content
SpringerLink
Log in

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

  • Research Article
  • Published:
Frontiers of Mechanical Engineering Aims and scope Submit manuscript

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wong C C, Dean T A, Lin J. A review of spinning, shear forming and flow forming process. International Journal of Machine Tools & Manufacture, 2003, 43(14): 1419–1435

    Article  Google Scholar 

  2. Xia Q X, Xiao G F, Long H, et al. A review of process advancement of novel metal spinning. International Journal of Machine Tools & Manufacture, 2014, 85: 100–121

    Article  Google Scholar 

  3. Zhan M, Yang H, Guo J, et al. Review on hot spinning for difficultto-deform lightweight metals. Transactions of Nonferrous Metals Society of China, 2015, 25(6): 1732–1743

    Article  Google Scholar 

  4. Ma F, Yang H, Zhan M. Plastic deformation behaviors and their application in power spinning process of conical parts with transverse inner rib. Journal of Materials Processing Technology, 2010, 210(1): 180–189

    Article  Google Scholar 

  5. Zhan M, Guo J, FuMW, et al. Formation mechanism and control of flaring in forward tube spinning. International Journal of Advanced Manufacturing Technology, 2018, 94(1–4): 59–72

    Article  Google Scholar 

  6. Zhang J H, Zhan M, Yang H, et al. 3D-FE modeling for power spinning of large ellipsoidal heads with variable thicknesses. Computational Materials Science, 2012, 53(1): 303–313

    Article  Google Scholar 

  7. Cao X W, Zhang L W, Yang Y T, et al. Progress of research on counter-roller forming. HotWorking Technology, 2013, 42(9): 115–117 (in Chinese)

    Google Scholar 

  8. Zhou X Y. Counter-roller spinning: A new process for manufacturing large tube with high strength and precision. Forging & Stamping Technology, 1993, 18(2): 49–51 (in Chinese)

    MathSciNet  Google Scholar 

  9. Xiao G F, Xia Q X, Cheng X Q, et al. Research on the grain refinement method of cylindrical parts. International Journal of Advanced Manufacturing Technology, 2015, 78(5–8): 971–979

    Article  Google Scholar 

  10. Grönert H, Eckert M, von Petersdorff H, et al. US Patent, 4766752, 1988-08-30

  11. Grönert H, Eckert M. US Patent, 4951490, 1990-08-28

  12. Yang H, Zhan M, Liu Y L, et al. Some advanced plastic processing technologies and their numerical simulation. Journal of Materials Processing Technology, 2004, 151(1–3): 63–69

    Article  Google Scholar 

  13. Zhang D W, Yang H, Sun Z C. 3D-FE modelling and simulation of multi-way loading process for multi-ported valve. Steel Research International, 2010, 81(3): 210–215

    Article  Google Scholar 

  14. Zhang D W, Zhao S D. Numerical study on forming complex fitting body on end of integrated stainless steel pipe without welds. Journal of Central South University, 2016, 23(2): 269–276

    Article  Google Scholar 

  15. Zhang D W, Zhao S D, Yang H. Analysis of deformation characteristic in multi-way loading forming process of aluminum alloy cross valve based on finite element model. Transactions of Nonferrous Metals Society of China, 2014, 24(1): 199–207

    Article  Google Scholar 

  16. Xiao Z Y, Zhang T. Rigid-plastic finite element analysis of opposite roller spinning. Forging & Stamping Technology, 1999, 24(1): 27–30 (in Chinese)

    Google Scholar 

  17. Xiao G F, Xia Q X, Cheng X Q, et al. Metal flow model of cylindrical parts by counter-roller spinning. Procedia Engineering, 2014, 81: 2397–2402

    Article  Google Scholar 

  18. Xi Q H, Fan W X, Lv W, et al. Orthogonal test of counter roller spinning by numerical simulation. Forging & Stamping Technology, 2016, 41(8): 154–158 (in Chinese)

    Google Scholar 

  19. Shan D B, Zhang Y Q, Wang Y, et al. Defect analysis of complexshape aluminum alloy forging. Transactions of Nonferrous Metals Society of China, 2006, 16(S3): 1574–1579

    Google Scholar 

  20. He M, Li F G,Wang Z G. Forming limit stress diagram prediction of aluminum alloy 5052 based on GTN model parameters determined by in situ tensile test. Chinese Journal of Aeronautics, 2011, 24(3): 378–386

    Article  Google Scholar 

  21. Wang X X, Zhan M, Guo J, et al. Evaluating the applicability of GTN damage model in forward tube spinning of aluminum alloy. Metals, 2016, 6(6): 136

    Article  Google Scholar 

  22. Altan T, Oh S I, Gegel H L. Metal Forming: Fundamentals and Application. Metal Park: American Society for Metals, 1983

    Google Scholar 

  23. Zhang D W, Yang H, Li H W, et al. Friction factor evaluation by FEM and experiment for TA15 titanium alloy in isothermal forming process. International Journal of Advanced Manufacturing Technology, 2012, 60(5–8): 527–536

    Article  Google Scholar 

  24. Zhang D W, Ou H. Relationship between friction parameters in Coulomb-Tresca friction model for bulk metal forming. Tribology International, 2016, 95: 13–18

    Article  Google Scholar 

  25. Zhang D W, Cui M C, Cao M, et al. Determination of friction conditions in cold-rolling process of shaft part by using incremental ring compression test. International Journal of Advanced Manufacturing Technology, 2017, 91(9–12): 3823–3831

    Article  Google Scholar 

Download references

Acknowledgements

This work was supported in part by the National Natural Science Foundation of China (Grant Nos. 51675415 and 51335009).

Author information

Authors and Affiliations

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

    Dawei Zhang, Fan Li, Shuaipeng Li & Shengdun Zhao

Authors
  1. Dawei Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fan Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shuaipeng Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shengdun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dawei Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, D., Li, F., Li, S. et al. Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts. Front. Mech. Eng. 14, 351–357 (2019). https://doi.org/10.1007/s11465-019-0528-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11465-019-0528-z

Keywords

Search

Navigation