Skip to main content
SpringerLink
Log in

Investigation on spinnability of profiled power spinning of aluminum alloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Profiled power spinning is a complex metal forming process as there are many factors interrelated. The spinnability plays an important role in predicting fracture and controlling the shape of the profiled component. In this paper, a 3D finite element (FE) model is established so as to investigate on the spinnability of the ellipsoidal power spinning. The variation of the equivalent stress and the equivalent plastic strain are analyzed, and the analysis of variance takes comprehensive influence on the spinnability into consideration. The fracture behaviors of the ellipsoidal components are analyzed with the Johnson–Cook fracture criterion. The results show that the equivalent stress and the equivalent plastic strain increase with the forming time. As for the mono-factor influence, the spinnability is improved when the feed rate of the rollers decreases or the friction coefficient increases. As for the multi-factor influence, the interaction between the feed rate and the friction coefficient has a significant effect on the spinnability. The initial fracture is presented in the fillet part between the blank and the mandrel where the equivalent plastic strain reaches the maximum, the stress triaxiality is the minimum, and the Johnson–Cook damage initiation criterion approach one. The simulation results using the Johnson–Cook fracture criterion are in a good agreement with the experimental results during the ellipsoidal power spinning.

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. Schubert E, Klassen M, Zerner I, Walz C, Sepold G (2011) Light-weight structures produced by laser beam joining for future applications in automobile and aerospace industry. J Mater Process Technol 115:2–8

    Article  Google Scholar 

  2. Avitzur B, Yang CT (1960) Analysis of power spinning of cones. J Eng Ind 82:231–244

    Article  Google Scholar 

  3. Quigley E, Monaghan J (2000) Metal forming: an analysis of spinning processes. J Mater Process Technol 103:114–119

    Article  Google Scholar 

  4. Music O, Allwood JM, Kawai K (2010) A review of the mechanics of metal spinning. J Mater Process Technol 210:3–23

    Article  Google Scholar 

  5. Bai Q, Yang H, Zhan M (2008) Finite element modeling of power spinning of thin-walled shell with hoop inner rib. Trans Nonferrous Metal Soc 18:6–13

    Article  Google Scholar 

  6. Molladavoudi HR, Djavanroodi F (2011) Experimental study of thickness reduction effects on mechanical properties and spinning accuracy of aluminum 7075-O, during flow forming. Int J Adv Manuf Technol 52:949–957

    Article  Google Scholar 

  7. Kalpakcioglu S (1961) A study of shear-spinnability of metals. J Eng Ind 83:478–483

    Article  Google Scholar 

  8. Wong CC, Dean TA, Lin J (2003) A review of spinning, shear forming and flow forming processes. Int J Mach Tools Manuf 43:1419–1435

    Article  Google Scholar 

  9. Kegg RL (1961) A new test method for determination of spinnability of metals. J Eng Ind 83:119–124

    Article  Google Scholar 

  10. Kalpakcioglu S (1964) Maximum reduction in power spinning of tubes. J Eng Ind 86:49–54

    Article  Google Scholar 

  11. Hayama M, Murota T, Kudo H (1966) Deformation modes and wrinkling of flange on shear spinning. Bull JSME 9:423–433

    Article  Google Scholar 

  12. Chang SC, Huang CA, Yu SY, Chang Y, Han WC, Shieh TS, Chung HC, Yao HT, Shyu GD, Hou HY, Wang CC, Wang WS (1998) Tube spinnability of AA2024 and 7075 aluminum alloys. J Mater Process Technol 80–81:676–682

    Article  Google Scholar 

  13. Podder B, Mondal C, Kumara KR, Yadav DR (2012) Effect of preform heat treatment on the flow formability and mechanical properties of AISI4340 steel. Mater Des 37:174–181

    Article  Google Scholar 

  14. Huang CC, Hung JC, Hung C, Lin CR (2011) Finite element analysis on neck-spinning process of tube at elevated temperature. Int J Adv Manuf Technol 56:1039–1048

    Article  Google Scholar 

  15. Xia Q, Cheng X, Long H, Ruan F (2012) Finite element analysis and experimental investigation on deformation mechanism of non-axisymmetric tube spinning. Int J Adv Manuf Technol 59:263–272

    Article  Google Scholar 

  16. Xu Y, Zhang SH, Li P, Yang K, Shan DB, Lu Y (2001) 3D rigid-plastic FEM numerical simulation of tube spinning. J Mater Process Technol 113:710–713

    Article  Google Scholar 

  17. Parsa MH, Pazooki AMA, Ahmadabadi MN (2009) Flow-forming and flow formability simulation. Int J Adv Manuf Technol 42:463–473

    Article  Google Scholar 

  18. Hauk S, Vazquez VH, Altan T (2000) Finite element simulation of the flow-splitting-process. J Mater Process Technol 98:70–80

    Article  Google Scholar 

  19. Zhang J, Zhan M, Yang H, Jiang Z, Han D (2012) 3D-FE modeling for power spinning of large ellipsoidal heads with variable thicknesses. Comput Mater Sci 53:303–313

    Article  Google Scholar 

  20. Zhang JH, Yang H, Zhan M, Jiang HB (2011) Research on the stress and strain field and wall thickness in power spinning of ellipsoidal heads with variable thickness. Adv Mater Res 189–193:1960–1963

    Google Scholar 

  21. Sun JS, Lee KH, Lee HP (2000) Comparison of implicit and explicit finite element methods for dynamic problems. J Mater Process Technol 105:110–118

    Article  Google Scholar 

  22. Zhan M, Yang H, Zhang JH, Xu YL, Ma F (2007) 3D FEM analysis of influence of roller feed rate of roller on forming force and quality of cone spinning. J Mater Process Technol 187–188:486–491

    Article  Google Scholar 

  23. Adetoro OB, Wen PH (2010) Prediction of mechanistic cutting force coefficients using ALE formulation. Int J Adv Manuf Technol 46:79–90

    Article  Google Scholar 

  24. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48

    Article  Google Scholar 

  25. Huang L, Yang H, Zhan M, Liu Y (2008) Analysis of splitting spinning force by the principal stress method. J Mater Process Technol 201:267–272

    Article  Google Scholar 

  26. Huang L, Zeng R, Zhang X, Li J (2014) Study on plastic deformation behavior of hot splitting spinning of TA15 titanium alloy. Mater Des 58:465–474

    Article  Google Scholar 

  27. Chen MD, Hsu RQ, Fuh KH (2007) An analysis of force distribution in shear spinning of cone. Int J Mech Sci 47:902–921

    Article  MATH  Google Scholar 

  28. Low C, Hsu CM, Yu FJ (2003) Analysis of variations in a multi-variate process using neural networks. Int J Adv Manuf Technol 22:911–921

    Article  Google Scholar 

  29. Fazeli AR, Ghoreishi M (2011) Statistical analysis of dimensional changes in thermomechanical tube-spinning process. Int J Adv Manuf Technol 52:597–607

    Article  Google Scholar 

Download references

Author information

Author notes

  1. Liang Huang

    Present address: State Key Laboratory of Materials Processing and Die & Mould Technology, College of Materials Science and Engineering, Huazhong University of Science and Technology, No.1037 Luoyu Road, Wuhan, 430074, China

Authors and Affiliations

  1. State Key Laboratory of Materials Processing and Die & Mould Technology, College of Materials Science and Engineering, Huazhong University of Science and Technology, No.1037 Luoyu Road, Wuhan, 430074, China

    Rong Zeng & Jianjun Li

  2. Changzheng Machinery Factory, China Aerospace Science and Technology Corporation, Chengdu, 610100, China

    Fei Ma

Authors
  1. Rong Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fei Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Liang Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jianjun Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Liang Huang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zeng, R., Ma, F., Huang, L. et al. Investigation on spinnability of profiled power spinning of aluminum alloy. Int J Adv Manuf Technol 80, 535–548 (2015). https://doi.org/10.1007/s00170-015-7025-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7025-2

Keywords

Search

Navigation