Research On Design And Optimization Of Spinning Forming Device For Thin-Walled Parts With Non-circular Cross Section

Spinning forming technology is an integrated progressive forming technology.Compared with the traditional mold-based spinning forming process for circular cross-sections,the current spinning forming process and equipment for moldless,non-circular cross-section thin-walled parts as the future development direction still has poor quality,poor accuracy and stability,insufficient performance and poor process reliability.In response to the above problems,this paper proposes a new method for forming thin-walled parts with non-circular cross-sections and designs a spinning forming device for thin-walled parts with non-circular cross-sections based on this method.The specific research content and conclusions are as follows:First of all,based on the mechanical principle of swinging rod,a new method of spinning forming was put forward.By means of finite element and joint kinematics simulation,parts forming process parameters were studied,including the relationship between wheel speed and parts around the corner,rotary wheel and the contact time length of the parts and wheel feed speed and spinning forming device such as the relationship between the wheel structure size.It was concluded that the closer the size of the wheel structure was to the lower limit,the more stable the forming process was and the higher the forming precision was.Then the overall structure design of the non-circular spinning forming device was completed.Then,on the basis of the completion of the structural design,based on the rigid-flexible coupling theory method,the analysis of the force on the end effector of the non-circular spinning forming device and the motion state of the spinning wheel during the processing process was completed,and the flexibility of the key components was obtained Deformation was the biggest factor to affect the forming quality of parts,and the goal of subsequent structural topology optimization was determined;and according to the reliability of the uncertain factors of the complex system and the global sensitivity analysis method,the reliability and various aspects of the end actuator of the spinning forming device were solved.The importance of the input variables was measured,and the structural reliability of the spinning forming device designed in this paper was 94.9%.Among them,the dimensional error of the roulette structure had the greatest impact on the reliability of the end effector,thereby determining the design variables for structural topology optimization.Accordingly,based on the principle of structural topology optimization,the optimization goal of flexibility was minimized,and the optimal design of the roulette structure was completed.The optimization results showed that the structural flexibility was reduced by 71.83%,and the optimization goal of minimizing the structural flexibility was better achieved.Finally,the prototype of the spinning forming device for non-circular cross-section thin-walled parts had been developed,and the product trial production of non-circular cross-section thin-walled parts had been completed on this prototype.The part forming results showed that the spinning forming quality of non-circular thin-walled parts was good,and the reliability of the optimized device structure was 97.2%,which was an increase of2.3%.The rationality and reliability of the spinning forming device for non-circular section thin-walled parts independently developed in this paper was preliminarily confirmed.