Research On Forming Quality Of Conical Rotatory Parts With Continuously Variable Wall Thickness Of GH3030 Superalloy During Power Spinning

As a special manufacturing technology,power spinning has the advantages of good deformation condition,excellent performance of products,high material utilization,as well as wide range of products.Thus,it is widely used in aerospace,defense industry,home appliances and other areas.Conical rotatory parts with continuously variable wall thickness,one kind of sheet metal casing parts on aviation engine,are made of superalloy.They have the characteristics of thin wall thickness,complex shape and bad forming performance,etc.Considering the factors such as production efficiency,manufacturing cost and processing conditions,it is the best choice to use the power spinning technology to produce this kind of parts.Since our country is strongly supporting the development of aeroengine industry,it has a higher request for the quality of casing parts on aviation engine.In order to effectively control the deformation of the parts and realize the accurate forming of sheet metal casing parts on aviation engine,it is necessary to do the research in the aspects of forming mechanism,influence of key process parameters on forming quality and the optimization of process parameters for forming quality.Firstly,the load-displacement curve of GH3030 superalloy at ordinary temperature was obtained by tension tests.Based on load-displacement curve,the equation of true stress-strain curve of this material was built by means of formula derivation,data elimination and curve fitting.Secondly,the power spinning process of conical rotatory parts with continuously variable wall thickness of GH3030 superalloy was simulated,using SIMUFACT.FORMING software.In order to ascertain the forming mechanics,the distribution features were analyzed including equivalent stress,equivalent plastic strain,equivalent elastic strain,and plastic flow of the material.Thirdly,the evaluation indexes of flange planeness,circular degree of the external surface of cone barrel and comprehensive wall thickness deviation of forming part were respectively established in order to quantitatively study the influence of process parameters on the forming quality.Then,the single-factor analysis method was applied to study the influence of key process parameters on evaluation indexes including mandrel rotational velocity,roller feed rate,roller mounting angle and roller nose radius,so that the corresponding laws was obtained.Fourthly,taking the evaluation indexes as objects,the influence degree of process parameters on targets were studied and optimal process parameters were obtained based on uniform design method and simulations.Finally,power spinning experiments were conducted,and three-coordinates measuring machine was used to collect coordinates of sample points on experimental specimens,so that the evaluation indexes of experimental specimens for flange planeness and circular degree of the external surface of cone barrel were obtained.The conclusion that experimental results were in conformity with simulation results was arrived at,which verified the reliability of the simulation analysis.The study results can provide the theoretical evidence for realizing the accurate forming of sheet metal casing parts on aviation engine.