Abstract
How to form high-quality variable-section thin-walled conical parts through power spinning is a key issue for superalloy spinning manufacturing. A study into the hot power spinning deformation law of variable-section thin-walled conical parts and the effects of process parameters on surface straightness of forming quality are delineated in this paper. Through the establishment of finite element (FE) models using the single-factor and orthogonal design of experiments, the effects of four key process parameters on the surface straightness have been investigated and the optimal combination of process parameters have been yielded. These key factors include spinning temperature, roller nose radius, mandrel rotation rate and roller feed ratio. The results of FE simulation have been validated through the comparison of the surface straightness of modeled parts with those measured during a spinning experiment. The results reveal that, among the studied process parameters, the spinning temperature has the greatest influence on the surface straightness, followed by the roller nose radius and mandrel rotation rate, and the roller feed ratio has the least influence on the straightness. Larger mandrel rotation rate, smaller feed ratio and suitable spinning temperature can enhance the surface straightness.
Highlights
Spinning forming technology has the advantages of high product precision, excellent performance, high material utilization, small tonnage of equipment required and high process flexibility
The analysis of material flow law of variable-section conical spun parts proves that the metal does not move axially in the flat top area of the workpiece, and the axial displacement in the transition fillet area of the small end of the cone is small
The experimental result of the straightness tolerance of the cone outer surface was 1.52 mm, and the simulation result was 1.37 mm, with an error within 10%; the minimum error occurred in group 17
Summary
Spinning forming technology has the advantages of high product precision, excellent performance, high material utilization, small tonnage of equipment required and high process flexibility. Wang et al [16,17] studied the effects of roller path profiles and multi-pass spinning on the wall thickness variation and tool forces of parts in a conventional metal. Gan et al [19] developed a finite element model with parameterized conventional spinning roller paths based on quadratic Bezier curves, to explore the evolution of stress, strain and thinning of aluminum hemispherical parts during the backward processes. This paper uses GH4169 superalloy as the material to establish a finite element model for the hot power spinning of conical thin-walled parts with variable-sections. Through a single-factor and orthogonal experimental design, the effects of process parameters on the surface straightness of the workpiece were studied, and a variance analysis was performed to yield the optimal process parameter combination, providing a reference for the precise forming of the hot power spinning of conical parts with variable-sections.
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