Analysis And Research On The Spin Forming Process Of Tubeless Steel Wheel

In the study field of material processing abroad, variable cross-section tubeless steel wheels spinning technology has matured. But our theoretical research in this area is still relatively weak. In this paper, we used the finite element theory and three-dimensional modeling software UG to establish three-dimensional finite element model of the tubeless steel wheel rim and focus on the finite element numerical simulation analysis of the variable cross-section tubeless steel wheel rim in the whole forming process by using of software Deform, and finally got some accurate and valuable results.During the experiment, according to the research experience at home and abroad, we have established a variable cross-section tubeless steel wheel of the parts diagram. Because the calculation of blank size is same as the drawing process, as based on variable cross-section profile tubeless steel wheel size, according to the principles of the workpiece volume change, we have calculated the blank diameter and obtained the volume of cylindrical billet as 2904630mm3, and the shape size isï¿ 518mm * 9mm * 200mm.And the spinning wheel and mandrel model could be designed according to the size of blank which had been designed out. Spinning wheel, mandrel and blank model designed in the three-dimensional modeling software UG were imported into the finite element analysis software Deform for numerical simulation. In processing, the mandrel drives rough rotation, spinning wheel runs in the rotation while rotating around the mandrel, and the movement for radial feed is 23.5mm, forming a tapered profile tubeless steel wheels.By numerical simulation and analysis of variable cross-section tubeless steel wheel rim blank when forming the metal flow pattern and stress distribution and the impact on the material properties, tests were repeated to obtain reasonable parameters, and experimental results obtained are as follows. When the mandrel speed is 400r/min, spinning wheel speed is1rad/sec, the coefficient of friction between mandrel and the blank is 0.7 and the friction coefficient between the spinning wheel and the blank is about 0.1, the molding products of the variable cross-section tubeless steel wheel rims have good quality and no wrinkles and uneven ends and other defects appearing. When the mandrel speed is too high or too low or spinning wheel speed is too large, variable cross-section tubeless steel wheel rim formed parts will have the defects. Meanwhile, the coefficient of friction between the spinning wheel and the blank on the variable cross-section tubeless steel wheel rim has little effect on the quality of parts in forming.Finally, we provided the parameters above studies to spinning machine manufacturer and provided reliable production data for the package of equipment and tooling manufacturers of the variable cross-section tubeless steel wheel rim forming to confirm wheels' quality and improve its' production efficiency. It can promote and accelerate research progress of the spinning process areas of the variable cross-section of the tubeless steel wheel rim.