A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes
The special-shaped tank dome of a launch vehicle is a large, thin-walled, curved structure that is difficult to form using the conventional center-restraint spinning method. This study proposes a two-step marginal-restraint mandrel-free spinning method for forming large domes. The finite element ana...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-06-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/13/7/1205 |
| _version_ | 1797588280219271168 |
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| author | Lijun Zhu Cheng Huang Xinhe Li Xin Chang Yibo Li |
| author_facet | Lijun Zhu Cheng Huang Xinhe Li Xin Chang Yibo Li |
| author_sort | Lijun Zhu |
| collection | DOAJ |
| description | The special-shaped tank dome of a launch vehicle is a large, thin-walled, curved structure that is difficult to form using the conventional center-restraint spinning method. This study proposes a two-step marginal-restraint mandrel-free spinning method for forming large domes. The finite element analysis results indicate that a larger roller fillet radius and larger feed ratios lead to a larger upper convex angle and the minimum thickness value for the bottom contour. This study explored the impact of shape parameter variations on the upper convexity and transition rounding angle on forming accuracy. The results show that the convexity of the bottom of the special-shaped domes increases with a larger roller fillet radius and larger feed ratios while the overall height decreases. The forming accuracy is adversely affected by larger transition rounding angles and smaller upper convexities. For the accurate forming of domes, the mutual coupling influence during two-step forming should be considered, and a suitable process and suitable trajectory compensation parameters must be carefully selected. Finally, the study verified that a two-step marginal-restraint mandrel-free spinning method with a 10 mm roller fillet radius, a 2 mm/r feed ratio, and the corresponding trajectory compensation can achieve the precise forming of 2250 mm thin-walled special-shaped domes. |
| first_indexed | 2024-03-11T00:49:51Z |
| format | Article |
| id | doaj.art-6c9600f9df414e5bb22e5171748b9fe7 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-11T00:49:51Z |
| publishDate | 2023-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-6c9600f9df414e5bb22e5171748b9fe72023-11-18T20:29:24ZengMDPI AGMetals2075-47012023-06-01137120510.3390/met13071205A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank DomesLijun Zhu0Cheng Huang1Xinhe Li2Xin Chang3Yibo Li4Light Alloy Research Institute, Central South University, Changsha 410083, ChinaLight Alloy Research Institute, Central South University, Changsha 410083, ChinaLight Alloy Research Institute, Central South University, Changsha 410083, ChinaLight Alloy Research Institute, Central South University, Changsha 410083, ChinaLight Alloy Research Institute, Central South University, Changsha 410083, ChinaThe special-shaped tank dome of a launch vehicle is a large, thin-walled, curved structure that is difficult to form using the conventional center-restraint spinning method. This study proposes a two-step marginal-restraint mandrel-free spinning method for forming large domes. The finite element analysis results indicate that a larger roller fillet radius and larger feed ratios lead to a larger upper convex angle and the minimum thickness value for the bottom contour. This study explored the impact of shape parameter variations on the upper convexity and transition rounding angle on forming accuracy. The results show that the convexity of the bottom of the special-shaped domes increases with a larger roller fillet radius and larger feed ratios while the overall height decreases. The forming accuracy is adversely affected by larger transition rounding angles and smaller upper convexities. For the accurate forming of domes, the mutual coupling influence during two-step forming should be considered, and a suitable process and suitable trajectory compensation parameters must be carefully selected. Finally, the study verified that a two-step marginal-restraint mandrel-free spinning method with a 10 mm roller fillet radius, a 2 mm/r feed ratio, and the corresponding trajectory compensation can achieve the precise forming of 2250 mm thin-walled special-shaped domes.https://www.mdpi.com/2075-4701/13/7/1205mandrel-free spinmarginal-restraintaccurate formingtank dome parameters |
| spellingShingle | Lijun Zhu Cheng Huang Xinhe Li Xin Chang Yibo Li A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes Metals mandrel-free spin marginal-restraint accurate forming tank dome parameters |
| title | A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes |
| title_full | A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes |
| title_fullStr | A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes |
| title_full_unstemmed | A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes |
| title_short | A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes |
| title_sort | two step marginal restraint mandrel free spinning method for accuracy in forming large special shaped aluminum alloy tank domes |
| topic | mandrel-free spin marginal-restraint accurate forming tank dome parameters |
| url | https://www.mdpi.com/2075-4701/13/7/1205 |
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