3D FEM numerical simulation and experimental study on symmetric thin-wall tube neck-spinning

A 3D FEM model for symmetric thin-wall tube neck-spinning is established. The spinning process is simulated by means of ANSYS software, and the dynamic boundary and contact problems in simulation are solved. The transient stress distribution of contact area, the transient strain distribution of nodes in typical section and the strain distribution of the whole part at last are attained, and the place and the cause of crack are analyzed. Simulation results show how the strain distribution of typical section, the thickness of some typical nodes, the Z coordinate in typical section and the spinning force of three rollers change with the time. According to study the variation curve, the material flow law along radial, tangential and axial direction is attained and the whole spinning process is studied. The experiment data reflect how the spinning force is influenced by different process parameters, such as feed rate, roundness radius and pass reduction. The simulation and the experiment results supply criteria for optimum design and reasonable parameter selection.

Neck-spinning quality analysis and optimization of process parameters for plunger components:Simulation and experimental study

The plunger component is a key part of the plunger pump in the aircraft hydraulic system.Neck-spinning process is commonly used to fabricate plunger components,of which the quality of the spinning process significantly affects the performance of plunger pumps.One of the bottlenecks faced by the industry in the spinning process is to choose a suitable neck-spinning process so as to ensure the quality of plunger components.It is necessary to propose a reliable method to optimize the process parameters which affect the neck-spinning quality of plunger components.In this study,a calculable finite element analysis(FEA)model is established to simulate the threeroller neck-spinning process of the plunger component,which includes six typical slipper structures,two roller structures,and two spinning parameters.The FEA model is then validated by comparing the simulated spinning forces with the corresponding experimental results.The influence of the process conditions on the neck-spinning quality is investigated.And the orthogonal simulation results are analyzed by a combination of range method and fuzzy mathematical analysis method to recommend a reasonable slipper structure,roller structure and neck-spinning parameters.This study provides a promising method to improve the manufacturing quality of the typical plunger components.

MECHANISM RESEARCH FOR 3D NON-AXISYMMETRIC THIN-WALL TUBE OFFSET SPINNING

Difference of offset spinning with conventional symmetric spinning is analyzed. A 3D FEM model for offset tube neck-spinning is established and the spinning process is simulated by means of ANSYS software. Dynamic boundary and contact problems in simulation are solved. Transient stress distribution of contact area, transient strain distribution of nodes in typical section and strain distribution of the workpiece at last are attained, the place and the cause of crack are analyzed. Strain variation curves with time of offset spinning and conventional spinning are compared. It shows the mechanism difference between offset spinning and conventional spinning. In addition, simulation results show how strain distribution of typical section, thickness of some typical nodes, axial extension in left section and force of three rollers change with time. According to the study of the variation curve, material flow law along radial, tangential and axial direction is attained and the whole spinning process is studied. The simulation results discover that offset distance is the key to manufacture offset non-symmetric tube, and process parameters change with spinning angle. Experiment data really reflect different process parameters＇ influence on conventional symmetric and offset spinning force. Experiments accord well with simulation.