Microstructure Distribution Characteristics of High-Strength Aluminum Alloy Thin-Walled Tubes during Multi-Passes Hot Power Backward Spinning Process

The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning process as it can eliminate casting defects, refine microstructure and improve the plasticity of the tube. To analyze the microstructure distribution characteristics of the tube during the spinning process, a 3D coupled thermo-mechanical FE model coupled with the microstructure evolution model of the process was established under the ABAQUS environment. The microstructure evolution characteristics and laws of the tube for the whole spinning process were analyzed. The results show that the dynamic recrystallization is mainly produced in the spinning deformation zone and root area of the tube. In the first pass, the dynamic recrystallization phenomenon is not obvious in the tube. With the pass increasing, the trend of dynamic recrystallization volume percentage gradually increases and extends from the outer surface of the tube to the inner surface. The fine-grained area shows the states of concentration, dispersion, and re-concentration as the pass number increases. .

Variable-based Ramberg-Osgood constitutive model of power spinning bushing

The influences of power spinning process parameters on the mechanical properties of spinning parts were analyzed with an SXD100/3-CNC numerical control power spinning machine.The unidirectional tensile tests were carried out.Based on the experimental data,a ternary quadratic regression equation was established by orthogonal experiment.The Ramberg-Osgood constitutive model of tin-bronze connecting rod bushing was obtained.Referred to the constitutive relation of macroscopic incremental,the incremental elastoplastic constitutive relation of spinning parts was deduced based on the Mises yield criterion and kinematic hardening model.The results can be applied to the elastoplastic analysis in finite element numerical simulation.

ANALYSIS OF MECHANICS IN BALL SPINNING OF THIN-WALLED TUBE

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.

Effects of material properties on power spinning process of parts with transverse inner rib

Material properties of blank have a great effect on power spinning process of aluminum alloy parts with transverse inner rib.By using finite element(FE) and Taguchi method,the effects and significance of five key material parameters,namely,anisotropic index in thickness direction,yield strength,hardening exponent,strengthening factor and elastic modulus on the formability of inner rib,tendency of wall fracture and degree of inhomogeneous deformation of finished spun parts were obtained.The achievements provide an important guide for selecting reasonable spinning material,and are very significant for the optimum design and precision control of power spinning process of parts with transverse inner rib.

Application of BPANN in spinning deformation of thin-walled tubular parts with longitudinal inner ribs

Back-propagation artificial neural network (BPANN) is used in ball backward spinning in order to form thin-walled tubular parts with longitudinal inner ribs. By selecting the process parameters which have a great influence on the height of inner ribs as well as fish scale on the surface of the spun part, a BPANN of 3-8-1 structure is established for predicting the height of inner rib and recognizing the fish scale defect. Experiments data have proved that the average relative error between the measured value and the predicted value of the height of inner rib is not more than 5%. It is evident that BPANN can not only predict the height of inner ribs of the spun part accurately, but recognize and prevent the occurrence of the quality defect of fish scale successfully, and combining BPANN with the ball backward spinning is essential to obtain the desired spun part.

Spinning Deformation Criteria of Thin-walled Tubular Part with Longitudinal Inner Ribs

As a successive and local plastic deformation process, backward ball spinning was applied for the purpose of prodacing thin-walled tubular parts with longitudinal inner ribs. According to the local plastic deformation theoo,, the application of yield criterion to the spinning process and the influence of the radial spinning force component on the formability of inner ribs were analyzed. Based on yield criterion and plastic mechanics, the stable flow rule of metal material and forming criteria of the inner ribs were obtained aad conformed to the experimental results so as to contribute greatly to improving the ball spinning process and optimizing the process variables, such as the diameter of ball, the reduction in a pass and the wall thickness of tubular blank, which have a significant influenee on the formability of the inner ribs. The knowledge of the influence of the process variables such as the diameter of ball, the reduction in a pass and the wall thickness of tubular blank on the spinning process is essential to preventing the quality defects of the spun parts and obtaining the desired spun parts.

Microstructure evolution and corrosion resistance of AZ31 magnesium alloy tube by stagger spinning

This study fabricates an AZ31 magnesium alloy tube by spinning technology-power stagger forward spinning.The microstructure evolution of the tube is investigated by combining electron backscatter diffraction and transmission electron microscopy analysis,and the corrosion resistance is measured by an electrochemical corrosion test.Results show that the grains are obviously more uniform and finer along the wall thickness’s direction of the AZ31 alloy tube after the third spinning pass.The number of twins ascends first and then descends,while the varying trend of low-angle grain boundaries(LAGBs)is opposite to that of the twins as the spinning pass increases.With the increase of the total spinning deformation,the deformation texture initially increases and the c-axis of the{0001}crystal plane gradually rotates to the axial direction of the tube;the deformation texture then decreases and the orientation of grains becomes more random.The main mechanism of grain refinement is dynamic recrystallization by the twin-induced way and bowing out of the nucleation at grain boundaries during the first and second pass.However,the dominant mechanism of the refined grain is the high-temperature dynamic recovery in the third pass,and the microstructure mainly consists of substructured grains.After the spinning deformation,the corrosion resistance of the AZ31 alloy tube decreases due to the combined effect of twins and high density-dislocations.

Key Problems of Cold Power Spinning of Ti-15-3 Alloy

The key problems of cold power spinning of Ti-15-3 alloy are studied. Reasonable billet preparation methods are presented to improve crystal structure and avoid crack of billet. Influences of original wall thickness, reduction rate and feed rate on expanding in diameter are analyzed and some methods to prevent expanding in diameter are given.

Effect of power spinning and heat treatment on microstructure evolution and mechanical properties of duplex low-cost titanium alloy

The microstructural evolution and mechanical properties of low-cost Ti-5.5Al-1Fe-3.5Cr-3.2Zr-0.2Si al-loy during power spinning and after three types of heat-treatment routines(low-temperature anneal-ing,high-temperature annealing,solution and annealing)were systematically studied.An effective heat-treatment routine to fabricate high-strength and acceptable ductile as-spun Ti-5.5Al-1Fe-3.5Cr-3.2Zr-0.2Si alloy tubes was then proposed whereby the relationship between the mechanical performances and mi-crostructures was analyzed.The{0002}_(α)and{001}_(β)textures were formed after multi-pass power spin-ning.The as-spun LC-Ti alloy exhibited a good combination of strength and elongation after heat treat-ment at 550℃for 4 h,which was ascribed to the large plastic induced low-temperature spheroidization of deformedαphase and nanoscaleαprecipitation from deformedβphase.However,the elongation de-creased evidently when Zr2Si/TiCr2 participated at the interphase boundaries after heat treatment at 550℃for 8 h.In high-temperature annealing,the elongation changed nonlinearly owing to the precipitation of Zr2Si particles at triangular grain boundaries treated at 750℃for 1 h,and the spheroidization of the deformedα_(p)phase.Under solution and annealing conditions,lenticularαs would participate from the metastableβgrains,which contributed to the greatest strength albeit poor ductility.This study provides an effective guidance for the processing and application of the low-cost titanium alloy.

Elasto-Plastic FEM Analysis of Residual Stress in Spun Tube

The residual stress distribution of Hastelloy C corrosion-resistant alloy tubes after power spinning was simulated with the elasto-plastic finite element method combining with the element birth and death technique, the influences of spinning parameters on the distribution of the residual stress were investigated in detail, and the formation mechanism of residual stress during tube spinning was discussed. Based on the calculation of the residual stress, the reasons for annealing cracks on the spun tube during interpass heat treatment were explored. The simulation results and the characteristics of annealing cracks show that the circumferential residual tensile stress is a main factor to cause the annealing cracks.

New forming method of manufacturing cylindrical parts with nano/ultrafine grained structures by power spinning based on small plastic strains

A new spinning method to manufacture the cylindrical parts with nano/ultrafine grained structures is proposed, which consists of quenching, power spinning and recrystallization annealing. The microstructural evolution during the different process stages and macroforming quality of the spun parts made of ASTM 1020 steel are investigated. The results show that the microstructures of the ferrites and pearlites in the ASTM 1020 steel are transformed to the lath martensites after quenching. The martensite laths obtained by quenching are refined to 87 nm and a small amount of nanoscale deformation twins with an average thickness of 20 nm is generated after performing a 3-pass stagger spinning with 55% thinning ratio of wall thickness, where the equivalent strain required is only 0.92. The equiaxial ferritic grains with an average size of 160 nm and nano-carbides are generated by subsequent recrystallization annealing at 480°C for 30 min. The spun parts with high dimensional precision and low surface roughness are obtained by the forming method developed in this work, combining quenching with 3-pass stagger spinning and recrystallization annealing.