Study On The Forming Process Of The Outer Groove Of The Thick Wall Cylinder By Two Wheel Spinning

Lightweight technology has been a research hotspot for more than ten years,involving many fields such as military industry,aerospace,automobile,etc.it is of great significance to research and develop lightweight components and their forming technology.It is an important means to realize the lightweight of automobile parts through optimizing the structure of parts or upgrading the manufacturing process.Thick-walled cylindrical parts with annular outer grooves,such as pistons,are widely used in automobile transmission systems.Their traditional manufacturing methods have low efficiency and material utilization and need large wall thickness,which is against lightweight.As an advanced near net forming technology,spinning has the advantages of small forming force,high material utilization,high forming efficiency,high dimensional accuracy and good mechanical properties.Compared with the traditional method,the annular groove with spinning method is more efficient,and its wall thickness is smaller,which is conducive to lightweight and in line with the development trend of green and efficient modern production.In this paper,the thick wall cylinder parts with external grooves are formed by radial double wheels spinning.The orthogonal scheme and corresponding dies are designed to carry out experiments.The relative range analysis and variance analysis are conducted.The influence of the process parameters on the forming of workpiece are studied,including?(the ratio of applied stress to yield stress),?(the ratio of the feed distance and wall thickness of the spinning wheel within one cycle of the billet rotation)and₀(the billet wall thickness).And the effect mechanism of process parameters on the forming is further investigated by numerical simulation and theoretical analysis.In the process of forming,the material in the groove of billet flows to other areas,which leads to reducing of groove thickness and the material accumulation on the outer surfaces of the groove edges.The results of range analysis and variance analysis show that the process parameter?has no significant effect on the forming,the process parameters?and₀ have important effects on the forming quality of the workpiece,such as the bulge defect,and the thickness reduction in groove area.Combining the finite element technology with theoretical analysis,it is found that a larger?and a smaller₀ are beneficial to reduce the outflow of materials at the groove and the height of bulge on the groove edges.