Experimental Research On The Dieless Spinning Of Thin-walled Part With Double Cones

Conical hollow parts are widely used in aviation,aerospace and weapon industry.The forming methods are varied,due to the different materials and sizes,but spinning is most suitable for thin-walled cone which is sharp and deep,and it is widely used in the realistic production.In this thesis,a thin-walled part with double cones is formed by dieless spinning based on process analysis and theoretical analysis to investigate the deformation characteristics of metal,probably occurred quality problems as well as their influence factors and solutions.And at last the optimum forming process is obtained.This thesis first investigates the deformation characteristics,dividing circle diameter of the conventional spinning and the shear spinning,and the spinning force computing method.Cutting material size and preliminary forming scheme are determined according to process analysis,and the possible occurred quality problems,as well as their reasons and solutions are examined.This thesis investigates the deformation law of two cones through the wall-thickness measurement and mesh deformation analysis.On this basis,four quantitative control indexes of precision of component dimensions and their measuring method are established,the main influencing factors are determined.At last,process parameters of forming is optimized and proved by experiment with orthogonal test and RSM.The experimental results show that there are two kinds of forming zones(conventional spinning and shear spinning)during the dieless spinning of cone.It produces conventional spinning which may lead to wrinkling nearby the edge of the blank.The spindle speed and the feed rate of the roller have great influence on the forming.If the feed rate of the roller is too small,it leads to crack;if the feed rate of the roller is too large,it leads to wrinkling.The results of orthogonal test and RSM show that the one of RSM is better than that of orthogonal test,and the optimum parameters array like this:the spindle speed of the small cone is 560r/min,the spindle speed of the big cone is 668 r/min,the roller feed rate of the forepart small cone is 0.89mm/r,the roller feed rate of the backend small cone is 0.64mm/r,the roller feed rate of the big cone is 0.034mm/r.The actual experiment results of optimum process parameters show that the forming of double cones is satisfactory and the wall thickness of the two cones meet the sine law.