Finite-Element Modelling of Double-Roller Clamping Spinning of Wind Concentrator

Xueyong Qu,Yi Hua,Shengdun Zhao,Shuqin Fan,Hongzhong Xu,Xiaole Cheng

doi:10.3389/fenrg.2021.741703

Abstract

In order to improve the unit-power of a wind-driven generator, a wind concentrator with complex shape is installed in front of the impeller, which makes the airflow integrated and accelerated. It is important to manufacture the wind concentrator with high precision. The double-roller clamping spinning (DRCS) is a dieless, flexible spinning process that is very suitable for forming a wind concentrator with complex shape. The profile of a wind concentrator is divided into two parts: the contraction section and the expanding section. The process routes of both the contraction section and the expanding section are determined, and roller path equations are derived. Then the finite element (FE) analysis model that can describe the plastic deformation behavior of the DRCS forming for a wind concentrator is established, and the DRCS process of the flange is simulated. Furthermore, the wall-thickness distribution on the expanding section during the forming process is obtained. Finally, the reliability of the FE model is verified using the experimental results.

Highlights

To relieve the energy crisis, more and more new energy sources have been developed, such as wind energy, solar energy, hydrogen energy, and so on
FORMING PROCESS ROUTE OF A WIND CONCENTRATOR. Both the contraction section and expanding section of the diffusion ventilation section in the wind concentrator can be formed by the double-roller clamping spinning (DRCS) process
Two cylindrical rollers are used in the single-pass DRCS process, which causes the line contact between the roller and the sheet metal

Summary

INTRODUCTION

To relieve the energy crisis, more and more new energy sources have been developed, such as wind energy, solar energy, hydrogen energy, and so on. A new double-roller clamping spinning (DRCS) process is suitable for forming the wind concentrator with a complex profile. Before the DRCS process, a thin-walled cylindrical workpiece is fixed on the internal expanding clamp, DRCS of Wind Concentrator. Both the contraction section and expanding section of the diffusion ventilation section in the wind concentrator can be formed by the DRCS process. During both forming processes, several AC servo motors are used to control the path of the roller. Remove the straight side used for clamping, and the wind concentrator with a complex profile is obtained

DESIGN OF ROLLER PATH

CONCLUSION