Numerical Simulation And Experimental Analysis Of Power Spinning

Spinning technology has been used widely in the machining process of axially symmetrical workpiece, such as wheels, lampshades, missile shells, etc. Some process defects easily appeared in the production, such as cracking, peeling, bulging. So the research of forming mechanism and deformation regularities become to a key problem urgently to be solved.The finite element model of the spinning process for cone parts and wheel spokes were established. ANSYS/LS-DYNA was used to carry out numerical simulation. Combined with the experiment, spinning deformation mechanism was researched. The influence of process parameters to the forming process and workpiece quality was analyzed.Spinning process features was analyzed firstly. Based on plastic deformation theory and finite element technology, finite element model of spinning forming was established using ANSYS/LS-DYNA. Volume mesh and area mesh were compared in modeling. Some key problems, such as contact and path of the roller, were solved by using axle of the roller, array and coordinate operations. Data interruption in computing was adjusted. Some measures, such as adjusting element type, increasing the stiffness of deformable objects and gap of parts, were adopted to improve problems like negative volume, penetration and mesh distortion. The establishment of the finite element model laid the foundation for the research of deformation regularities and process parameters.The deformation features and regularities of stress-strain distribution of cone parts and wheel spokes were analyzed based on the finite element model. The influence of process parameters to spinning forming was analyzed. In cone part spinning, the influence of stress and strain to center hole of blank and forming accuracy was analyzed. The strain differences of internal and external surface were analyzed. The influence of process parameters, such as roller feed rate and deviation rate to stress-strain and forming quality, was analyzed. The reasons of defect, such as crack and peeling, were explained. In spoke spinning, the regularities of stress-strain distribution were obtained. The influence of process parameters, such as roller fillet radius, setting angle and spindle speed to stress-strain, wall thickness and wall thickness reduction was analyzed. The location of excessive reduction and cracking was forecasted.Some experiments were carried out according to the simulation results. Good quality workpiece was obtained using the optimized parameters.