Research On Spinning Equipment And Process Parameters Of Thin-walled 1060 Aluminum Cone Parts

Aluminum alloy is widely used in many kinds of thin-walled conical parts because of its low density,high specific strength and good plasticity.Generally,stamping technology is used in forming concave parts,but when using this technology to process thin-walled conical parts,the corresponding stamping die should be designed according to the shape and size of the formed parts.In most cases,a single pass can not complete the forming of the workpiece,and multi-pass processing is required,which leads to more complex process flow and increases economic cost.The spinning forming technology can realize the point contact with the metal blank through the spinning wheel,so that the material can obtain more pressure in the forming process,realize the plastic deformation of the blank from point to line and then to the surface.At the same time,the action direction of the roller and the blank can be adjusted to control the flow direction of the material.Therefore,the process flow is simplified,the forming efficiency is improved and the economic cost is reduced.For spinning forming technology,spinning equipment is the key.Due to the defects such as wrinkling,cracking and rippled peeling,the further development of spinning equipment is restricted by these problems.The traditional spinning equipment requires the operator need rich processing experience,which is not suitable for ordinary personnel.Meanwhile,the stability of the spinning equipment is poor,the material utilization rate is low,and there are some hidden dangers.However,most of the existing spinning equipment has a complex structure and requires high requirements for operators in the process of use.If the equipment is not operated properly,it will cause damage to the equipment and cause huge economic losses.In view of these problems,a new thin-walled aluminum alloy spinning equipment is designed in this project.On the basis of ensuring the forming accuracy,the complexity of the existing equipment is reduced,and the parts can be disassembled and replaced easily.By means of motor driving the screw to drive the rotary wheel,the efficiency of blank forming is improved and the possibility of operators being scratched by the blank is reduced,which is conducive to improving the stability and reliability of the equipment and reducing the cost of the equipment.Aiming at the problems of manual operation error and accuracy in the process of adjusting the process parameters of spinning equipment,the core die drive system and the roller motion control system improves the quality of the blank spinning.Aiming at the spinning forming of thin-walled aluminum alloy conical parts,the influence of process parameters on the formability and shape and dimension of the blank is analyzed from two aspects of the feed ratio of the roller and the installation angle of the roller,and the process parameters with the optimal quality of the formed workpiece are obtained.When the roller feed ratio is 0.011mm/r and 0.022mm/r,the flange wrinkling and corrugated peeling appear respectively.When the roller installation angle is 20 ° and 30 °,the spinning workpiece appears circumferential fracture defects.Under these parameters,it is not conducive to the spinning forming of blank.In addition,through the analysis of the defects conducive to the spinning forming of blank.In addition,through the analysis of the defects of the forming parts,the following laws are obtained:(1)Too small roller feed ratio will increase the circumferential compressive stress in the deformation zone of the blank,resulting in material accumulation and flange wrinkling defects on the surface of the formed workpiece.Too large roller feed ratio will cause material accumulation and bulge,and form a rough conical surface with folded spiral pattern.(2)Too small roller angle will increase the radial spinning pressure of the roller pair,resulting in material accumulation and circumferential fracture on the surface of the formed workpiece.Too large roller angle will increase the axial rotation pressure of the roller pair,resulting in material accumulation and circumferential fracture on the surface of the formed workpiece.(3)Through spinning experiment,it is found that the quality of the conical workpiece is the best when the feed ratio of the spinning wheel is 0.017mm/r,the spindle speed is 540r/min,the installation angle of the roller is 30 °,the gap deviation rate is-4%,the radius of the roller fillet is 2 mm,and the friction coefficient is 0.1.