Multiple Balls Spinning Forming Technology And Numerical Simulation Research

The traditional stamping technology with integer rigid mould serves with high cost and long time in one production cycle, and all types of surface need to be made with the corresponding mold, this leads to low production efficiency and high manufacturing cost. So we hope to find a relatively inexpensive way to produce small quantities of individual parts, less processing of mold and die is the goal of our pursuit, but in order to ensure enough processing precision, we adopt the method of half die forming, multiple balls spinning forming.Multiple balls spinning forming use free flowing steel ball as spinning forming tool, in “discrete” thought, the upper die can replace by discrete multiple balls which can form moduling surface, however the low die remains integer mould that is called ”Half Flexible Mould”. Realization of flexible forming of curved surface parts, the forming method not only can realize part’s pressure forming, also can reduce plate forming part’s springback by the toggle ball’s spinning to improve the paster precision.In this paper, the corresponding model is established by using the ABAQUS finite element software, and the simulation of the forming process is simulated by two kinds of forming methods, the ball spinning after pressing and the ball pressing and spinning. Study the effect of different parameters on the forming performance of the multiple balls spinning forming process by comparing the stress and strain on the plate during the forming process, we can get the following conclusion:1.In the ball spinning after pressing and the ball pressing and spinning of the two forming methods, when using the former forming method, the whole stress of the plate increases to the maximum value with the steel ball pressing, and then decreases to a certain value with the spinning of the steel ball. When use the steel ball pressing and spinning, the whole stress value of the plate is gradually increased to a certain value, and then remains unchanged. At the end of the forming process, the stress of the shaped part of the ball spinning after pressing is smaller, and strain is bigger.2.In the ball spinning after pressing model, when mixing the two kinds of steel balls with different diameters, the stress and strain of the shaped part is between of the use of two kinds of steel ball shaped parts, and the distribution is more uniform; reducing the spinning speed of the steel ball can effectively reduce the stress value of the shaped part, and the strain of the forming area is increased, the distribution is more uniform; Increasing the number of spinning can effectively reduce the overall stress of the shaped part and increase the strain in the forming region. In the ball pressing and spinning model, when two kinds of steel balls with different diameters are mixed, the stress and strain values are between of two kinds of steel balls, but the distribution is more uniform; reducing the spinning speed of the steel ball, the stress and strain of the shaped part is increased.3.In the ball spinning after pressing and the ball pressing and spinning of the two forming methods of the springback, the residual stress of the shaped part in the ball spinning after pressing is larger, but it is more uniform and the spring back is smaller. In the ball spinning after pressing model, the springback effect of the shaped part with the ball mixed is better; Reducing the spinning speed of the steel ball can reduce the residual stress of the shaped part,and the springback effect is good; Properly increasing the number of spinning of steel balls can effectively reduce the residual stress of the shaped part, the formability is good.In the model of ball pressing and spinning, the residual stress of the shaped part with the mixed action of the ball is in the middle, and the springback effect is good; When the speed of the steel ball of pressing and spinning is reduced, the residual stress of the shaped part is increased and the springback effect becomes worse.