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Frontiers of Mechanical Engineering

Front. Mech. Eng.    2019, Vol. 14 Issue (3) : 351-357
Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts
Dawei ZHANG(), Fan LI, Shuaipeng LI, Shengdun ZHAO
School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
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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.

Keywords large-sized cylindrical part      counter-roller spinning      aluminum alloy      finite element method      distributed power     
Corresponding Author(s): Dawei ZHANG   
Just Accepted Date: 20 November 2018   Online First Date: 21 December 2018    Issue Date: 24 July 2019
 Cite this article:   
Dawei ZHANG,Fan LI,Shuaipeng LI, et al. Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts[J]. Front. Mech. Eng., 2019, 14(3): 351-357.
Fig.1  Sketch of counter-roller spinning
Strain rate/s−1 Yield strength/MPa Compressive strength/MPa
0.01 145.3 463.4
0.05 176.3 548.5
Tab.1  Main parameters of aluminum alloy 5052
Fig.2  FE model of the CRS process (backward spinning process with four pairs of rollers): (a) Assembly relations of geometry models and (b) local fine mesh of the tubular blank/workpiece
Fig.3  Shape of the compressed ring of aluminum alloy 5052: (a) Lubricated condition and (b) dry friction
Fig.4  CRS process with two pairs of rollers: (a) 3D-FE model, (b) spinning experiment, and (c) structure of the roller (unit: mm)
Parameter Value
Material Aluminum alloy 5052
Outer diameter of the tubular blank 720 mm
Outer thickness reduction ratio 20%
Inner thickness reduction ratio 15%
Axial infeeding speed of the roller 1 mm/r
Rotational speed of the workpiece 45 r/min
Friction condition Lubricated condition (m=0.15)
Tab.2  Main parameters in the counter-roller spinning experiment
Fig.5  Shape of the cylindrical part after spinning: (a) Experimental result and (b) numerical result
Fig.6  Distribution of wall thickness
Fig.7  Distribution of field variables: (a) Effective stress and (b) effective strain
Fig.8  Force and torque of counter-roller spinning for a 6 m aluminum alloy cylindrical part: (a) Spinning force of the roller and (b) torque of the turntable
Fig.9  3D model of the vertical counter-roller spinning machine
Fig.10  Rotation mechanism of the tubular blank/workpiece: (a) Overall layout, (b) one double-geared-roll appliance, and (c) double-geared roll
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