Abstract
In view of the importance of the surface quality in the application to the square section die-less spinning, the effects of several key parameters which include roller path, half-cone angle, and roller nose radius on the surface quality are investigated. Through the geometric model of residual height, the effect law of the roller path is obtained: the surface quality increases with the decrease of the axial distance of two adjacent slices. Then the finite element model of the square section die-less spinning is established, and the normal force and axial strain states in the deforming process are adopted to predict the relationship between the surface quality and the half-cone angle. Combined with the residual height model and finite element analysis, the roller nose radius’ effect on the surface quality is also obtained. Enlargement of the two parameters can improve the surface quality. All the analysis results are verified by the surface waviness test of the specimens from the workpiece after spinning.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Music O, Allwood JM, Kawai K (2010) A review of the mechanics of metal spinning. J Mater Process Technol 210(1):3–23
Kang DC, Gao XC, Meng XF, Wang ZH (1999) Study on the deformation mode of conventional spinning of plates. J Mater Process Technol 91(1):226–230
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(9–12):949–957
Gao XC, Kang DC, Meng XF, Wu HJ (1999) Experimental research on a new technology—ellipse spinning. J Mater Process Technol 94(2):197–200
Xia Q, Shima S, Kotera H, Yasuhuku D (2005) A study of the one-path deep drawing spinning of cups. J Mater Process Technol 159(3):397–400
Xia QX, Cheng XQ, Hu Y, Ruan F (2006) Finite element simulation and experimental investigation on the forming forces of 3D non-axisymmetrical tubes spinning. Int J Mech Sci 48(7):726–735
Xia QX, Xie SW, Huo YL, Ruan F (2008) Numerical simulation and experimental research on the multi-pass neck-spinning of non-axisymmetric offset tube. J Mater Process Technol 206(1–3):500–508
BAI Q, YANG H, Zhan M (2008) Finite element modeling of power spinning of thin-walled shell with hoop inner rib. Trans Nonferrous Metals Soc China 18(1):6–13
Huang L, Yang H, Zhan M (2008) 3D-FE modeling method of splitting spinning. Comput Mater Sci 42(4):643–652
Huang L, Yang H, Zhan M, Hu LJ (2008) Numerical simulation of influence of material parameters on splitting spinning of aluminum alloy. Trans Nonferrous Metals Soc China 18(3):674–681
Huang L, Yang H, Zhan M, Hu L (2009) Forming characteristics of splitting spinning based on the behaviors of roller. Comput Mater Sci 45(2):449–461
Jiang S, Ren Z, Li C, Xue K (2009) Role of ball size in backward ball spinning of thin-walled tubular part with longitudinal inner ribs. J Mater Process Technol 209(4):2167–2174
Jiang SY, Zheng YF, Ren ZY, Li CF (2009) Multi-pass spinning of thin-walled tubular part with longitudinal inner ribs. Trans Nonferrous Metals Soc China 19(1):215–221
Shimizu I (2010) Asymmetric forming of aluminum sheets by synchronous spinning. J Mater Process Technol 210(4):585–592
Music O, Allwood JM (2011) Flexible asymmetric spinning. CIRP Ann Manuf Technol 60:319–322
Awiszus B, Härtel S (2011) Numerical simulation of non-circular spinning: a rotationally non-symmetric spinning process. Prod Eng 5(6):605–612
Sekiguchi A, Arai H (2012) Control of wall thickness distribution by oblique shear spinning methods. J Mater Process Technol 212(4):786–793
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(1):303–313
Xia QX, Lai ZY, Long H, Cheng XQ (2013) A study of the spinning force of hollow parts with triangular cross sections. Int J Adv Manuf Technol 68(9–12):2461–2470
El-Khabeery MM, Fattouh M, El-Sheikh MN, HAMED OA (1991) On the conventional simple spinning of cylindrical aluminum cups. Int J Mach Tools Manuf 31(2):203–219
Chen MD, Hsu RQ, Fuh KH (2001) Forecast of shear spinning force and surface roughness of spun cones by employing regression analysis. Int J Mach Tools Manuf 41(12):1721–1734
Chen MD, Hsu RQ, Fuh KH (2005) Effects of over-roll thickness on cone surface roughness in shear spinning. J Mater Process Technol 159:1–8
Kwiatkowski L, Tekkaya AE, Kleiner M (2013) Fundamentals for controlling thickness and surface quality during dieless necking-in of tubes by spinning. CIRP Ann Manuf Technol 62(1):299–302
Jia Z, Han ZR, Xu Q, Peng WF (2014) Numerical simulation and experiment study on hollow spinning process for square cross-section cone. Int J Adv Manuf Technol 75(9–12):1605–1612
Ma B, Tieu AK, Lu C, Jiang Z (2002) An experimental investigation of steel surface characteristic transfer by cold rolling. J Mater Process Technol 125–126(3):657–663
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jia, Z., Han, Z.R., Xu, Q. et al. Effects of processing parameters on the surface quality of square section die-less spinning. Int J Adv Manuf Technol 80, 1689–1700 (2015). https://doi.org/10.1007/s00170-015-7055-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7055-9