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Finite element simulation and experimental investigation on the forming forces of 3D non-axisymmetrical tubes spinning 总被引:4,自引:0,他引:4
3D non-axisymmetrical tube (NAT) spinning is a kind of new spinning technology, which breaks through the restriction that only axisymmetrical hollow parts could be produced by traditional spinning technology. The research on the spinning force aims to optimize the machine design and the processing parameters selection. The neck-spinning process of the 3D NAT is simulated by 3D elastic–plastic finite element software, MARC. The characteristics of the neck-spinning force of 3D NAT are compared with that of the axisymmetrical tube (AT) spinning. The effect of the main forming parameters, such as offset amount, oblique angle, nominal reduction of blank radius, feed rate and path direction, on the spinning forces have been studied theoretically and experimentally. It shows that during 3D NAT spinning, the spinning forces varies periodically with the revolution angle of the roller around the blank; the spinning force during backward path spinning is greater than that of forward path spinning. The simulation results conform well to the experimental ones. 相似文献
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XiaQinxiang SusumuShima 《机械工程学报(英文版)》2003,16(4):376-378
Flexible spinning is a new type of spinning process where spin-forming is performed without using a mandrel. Combining shearing and rolling processes, the calculation formulas of the spinning forces in flexible spinning of cones is presented. The effects of the main processing parameters, such as gripping force G applied to the blank by the inner roller, the feed rate of rollers f and theroundness radius of outer roller ro, on the spinning forces are analyzed experimentally and theorelically. 相似文献
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Xia QinxiangDepartment of Mechanical Engineering South China University of Technology Guangzhou ChinaSusumu ShimaDepartment of Mechanical Engineering Kyoto University Kyoto - Japan 《机械工程学报(英文版)》2003,16(4)
Flexible spinning is a new type of spinning process where spin-forming is performedwithout using a mandrel. Combining shearing and rolling processes, the calculation formulas of thespinning forces in flexible spinning of cones is presented. The effects of the main processing parame-ters, such as gripping force G applied to the blank by the inner roller, the feed rate of rollers f and theroundness radius of outer roller r_o, on the spinning forces are analyzed experimentally and theoreti-cally. 相似文献
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An analysis of force distribution in shear spinning of cone 总被引:1,自引:0,他引:1
Ming-Der Chen Ray-Quan Hsu Kuang-Hua Fuh 《International Journal of Mechanical Sciences》2005,47(6):902-921
An analytic model for calculation of shear spinning force incorporate factor of over-roll (press down) of the blank is derived. The effects of blank thickness, roller nose radius, mandrel revolution and roller feed on the spinning force are discussed. Results obtained from calculation were compared with the experiment and other theoretical predictions. It is found that the present findings yield optimum results. 相似文献
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工艺参数对平板毛坯普旋成形的影响规律 总被引:3,自引:0,他引:3
基于ABAQUS/Explicit平台建立了符合实际的普旋三维仿真模型,利用此模型对平板毛坯普旋成形过程进行了模拟,研究了旋轮进给率、旋轮圆角半径、旋轮入旋角、板料厚度4个关键参数对平板毛坯普旋(第一道次)成形过程及旋压件质量的影响。结果表明:入旋角对板料的壁厚变化有较大的影响;旋轮圆角半径和板料厚度仅对板料的壁厚减薄率影响较大,对板料的壁厚增厚率影响很小;当旋轮进给率的值较小时,旋轮进给率对普旋成形过程影响不大。基于以上研究,最后得到了合理的工艺参数取值。 相似文献
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Qihang Wang Lei Wang Zhiwei Jiang Shihua Gong 《The International Journal of Advanced Manufacturing Technology》2013,68(1-4):217-226
Spinning process is an effective and flexible method that has been widely employed to produce metal components having an axisymmetric rotational geometry, such as components for jet engines, turbines, radar reflectors, satellite nose cones, etc. Safe performance of mandrel and staff is critical to spinning process. In this paper, the safety aspects, i.e., temperature, leakage of hydraulic system, material deformation, roller path that related to spinning process operations, were in-depth analyzed. Moreover, a concept of mandrel protection curve was presented to avoid the potential dangers, and the relevance algorithm to generate mandrel protection curve was also developed. Then, based on the generation algorithm of mandrel protection curve, the redundant point problem was analyzed, and a new algorithm for rejecting redundant points was designed to enhance efficiency and safety. Finally, Multi-passes and constant linear velocity were adopted for higher product precision during complex spinning product manufacture. The common open-architecture CNC system and hydraulic servo system were used to realize the algorithm researches. The results show that the researched algorithms are effective to guarantee mandrel and staff’s safety and improve product precision. 相似文献
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Lanyun Li He Yang Lianggang Guo Zhichao Sun 《Journal of Mechanical Science and Technology》2007,21(10):1541-1547
Cold ring rolling is a much complex physical process with multi-factors. Two forming parameters, the feed rate of mandrel
and the rotational speed of main roll, affect the quality of deformed ring significantly and the feed amount per revolution
of ring in the form of their ratio. By their ratio, the interactive effects of the two forming parameters on the T-shaped
cold ring rolling process are explored through 3D-FEM in Abaqus software. The results show: firstly the study objects (roll
force, growth rate of diameter, degree of inhomogeneous deformation, filling capability of groove, average side spread and
fishtail coefficient) are almost invariable if the two parameters are increased (or decreased) proportionally; secondly whether
the ratio is changed by the feed rate of mandrel or by the rotational speed of main roll, the variation of each study object
with the ratio is approximately the same; thirdly the increase of the ratio is beneficial to the growth of diameter and the
restrictions of inhomogeneous deformation, average side spread and fishtail coefficient, but it causes the roll force to increase
and the filling capability of groove to decrease. 相似文献
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ANALYSIS OF MECHANICS IN BALL SPINNING OF THIN-WALLED TUBE 总被引:2,自引:1,他引:1
JIANG Shuyong REN Zhengyi 《机械工程学报(英文版)》2008,21(1):25-30
Ball spinning is applied to manufacturing thin-walled tube with high precision and high mechanical properties. On the basis of plastic mechanics, by simplifying ball spinning of thin-walled tube as plane strain problem, slab method is used for the purpose of calculating the contact deformation pressure. The spinning force components, the torsional moment, the deformation power and the deformation work are calculated further as well. The influence of the two important process parameters such as the feed ratio and the ball diameter on the spinning force components is analyzed in order to further control the spinning force components by regulating the two process variables during the ball spinning process. The stress and strain state in deformable zone as well as mechanics boundary conditions in ball spinning are obtained. The effect of the three spinning force components on the formability of the spun part is analyzed and validated through the ball spinning experiments. The theoretical and experimental results show that the radial spinning component plays a significant role in ball spinning of thin-walled tube, and the mechanics situation in backward ball spinning contributes to enhancing the plasticity of the metal material, but that in forward ball spinning contributes to advancing the axial flow of the metal material. 相似文献
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Statistical analysis of dimensional changes in thermomechanical tube-spinning process 总被引:2,自引:2,他引:0
A. R. Fazeli M. Ghoreishi 《The International Journal of Advanced Manufacturing Technology》2011,52(5-8):597-607
Tube-spinning process is an effective method for manufacturing long thin-wall tubes with precision dimensions and desired mechanical property. The main objectives of this research deal with the influences of major process parameters of thermomechanical tube-spinning process such as preform thickness, thickness reduction, mandrel rotational speed, feed rate of rollers, solution treatment time, and aging treatment time on internal diameter growth and wall thickness changes for manufacturing of 2024 aluminum spun tubes using design of experiments. Experimental results are analyzed by analysis of variance and empirical models of internal diameter growth and wall thickness changes are developed. It is found that lower thickness reduction with thinner preform thickness, higher feed rate of rollers, slower mandrel rotational speed, and lower solution treatment time have advantages for obtaining smaller internal diameter growth and wall thickness changes. 相似文献
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Amin Abedini Samrand Rash Ahmadi Ali Doniavi 《The International Journal of Advanced Manufacturing Technology》2014,72(5-8):1009-1019
The present study reports the effect of various flow-forming process parameters and roller geometry on the roughness of flow-formed tubes of commercial pure copper UNS C11000. Thickness reduction ratio, feed rate, angular speed of mandrel, attack angle of roller, roller tip radius, and smooth angle of roller were considered as variable parameters. The effects of these input parameters on the roughness have been critically analyzed using the Taguchi method. Through ANOVA analysis, it has been found that the roller tip radius is the most important parameter affecting roughness followed by thickness reduction ratio. Selection of an optimum combination of variable parameters was performed based on “average of results.” The minimum roughness of 1.37 μm was achieved when the process parameters were set at their optimum values. 相似文献
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N. A. Razani Abdolhossein Jalali Aghchai Bijan Mollaei Dariani 《The International Journal of Advanced Manufacturing Technology》2014,70(5-8):1463-1471
Flow forming is an advanced locally plastic deformation applied to manufacture seamless tubes with thin walls and high precision dimension. One of the important mechanical properties of flow-formed tubes is hardness. In this study, after preliminary experiments for definition of effective parameters, design of experiments (DOE) is utilized to determine the influence of the parameters such as rotational speed of mandrel, feed rate, and wall thickness reduction on the hardness of flow-formed AISI 321 steel tube. Under experimental results, a mathematical model comprising effective parameters is developed to predict the optimum hardness, using response surface methodology (RSM). RSM’s Box–Behnken design is employed to specify the optimum condition caused to a minimum hardness at high optimum confidence level. The analyzed model revealed that the hardness increases with increasing of the mandrel speed and the depth of cut, and it decreases with decreasing of the feed rate. The new point of view is related to the fact that the high level of thickness reduction covers the efficiency of mandrel speed. 相似文献
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Chung-Hyo Jung Jin-Tak Kim Yun-Ho Choi 《Journal of Mechanical Science and Technology》2011,25(6):1465-1474
An automatic washing machine undergoes rotational unbalance due to unbalanced mass during the spinning process. A liquid balancer
is an assembly that plays a role in controlling this unbalance. In recent years, washing machines (drum and automatic types)
are becoming larger to handle large laundry items such as comforters. A large-sized washing machine generates a huge centrifugal
force in its high speed rotating drum. Thus, a specific vibration reduction technique is required. The design of a liquid
balancer has, to date, depended on conventional methods such as experiments and dynamic models. A dynamic model classifies
the behavior of liquid inside the balancer into three different patterns, and solutions can be obtained by approximating these
patterns as rigid bodies. This method, however, is limited to two-dimensional (2-D) analysis for simple geometry. In the present
study, a three dimensional (3-D) computational fluid dynamics (CFD) method is used to analyze flow characteristics inside
the liquid balancer for various design parameters. The main parameters include rotational speed, eccentricities of the center
of rotation, viscosity of the liquid, gravity orientation, surface tension, and the number of baffles. In particular, the
effects of these parameters on the hydraulic force (restoration force) of the liquid balancer are studied. 相似文献
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基于傅里叶级数的非圆截面车削进给运动特征分析 总被引:1,自引:0,他引:1
提出了用于非圆截面车削进给机构运动特性的傅里叶分析技术方法,并分别对非圆截面形状特征和车削进给机构的速度、加速度等特性进行了分析,建立了进给机构的驱动力学模型。通过分析,能较准确的确定非圆截面零件的可加工性能及其难易程度,并为非圆截面车削进给系统的研制提取所需原始数据,有机地建立了非圆截面形状与车削进给机构运动特性之间的相互关系。 相似文献
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Z. Jia Z. R. Han Q. Xu W. F. Peng 《The International Journal of Advanced Manufacturing Technology》2014,75(9-12):1605-1612
Spinning process is investigated to reveal the mechanism of square cross-section spinning without mandrel. The finite element model with the roller path formula as a boundary condition is established. Forge3D software is used to simulate the spinning process, and the accuracy of the finite element model is verified through experiment. From the stress–strain field, the residual stress on the surface of the workpiece is small after square cross-section cone hollow spinning and the maximum deformation locates on the middle part of the slope surfaces of the workpiece. The strain field distribution and the same Δr in different rotation round are the cause of the slight curvature that appears on the cross-section edge. The wall thickness decreases after hollow spinning, and the upper wall thickness is larger than the lower part. 相似文献
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M. Srinivasulu M. Komaraiah C. S. Krishna Prasada Rao 《Journal of Mechanical Science and Technology》2013,27(6):1835-1842
Flow forming is a modern, chipless metal forming process that is employed for the production of thin-walled seamless tubes. Experiments are conducted on AA6082 alloy pre-forms to flow form into thin-walled tubes on a CNC flow-forming machine with a single roller. Design of experiments is used to predict the surface roughness of flow-formed tubes. The process parameters selected for this study are the roller axial feed, mandrel speed, and roller radius. A standard response surface methodology (RSM) called the Box-Behnken design is used to perform the experimental runs. The regression model developed by RSM successfully predicts the surface roughness of AA6082 flow-formed tubes within the range of the selected process parameters. 相似文献