Finite Element Simulation and Micro-Grain Size Analysis of Sheet Metal Casing by Hot Power Spinning

Abstract

Spinning is a typical continuous local plastic forming and an advanced manufacturing technology to achieve less cutting machining of thin-walled rotary parts. As the external bearing component of aero-engine, the mainstream manufacturing method of sheet metal casing is hot power spinning. Its forming quality includes dimensional, shape accuracy and macroscopic defects. The refinement and uniformity of micro grain size are also important indicators. The FE finite element) model of tapered sheet metal casing with variable wall thickness in hot power spinning was established by DEFORM-3D. The average deflection angle deviation Δθ and standard deviation of wall thickness error Δt was used as the evaluation indexes of 13 simulation schemes. The effect of the mandrel speed, the roller feed ratio, the roller fillet radius and the initial temperature on the forming quality was analyzed. Through the spinning experiment of SXY1000 double-roller CNC spinning machine, the metallographic structure of different forming regions and the micro grain size under different temperatures and roller feed ratios are explored. The micro grain size of the formed part is more refined with the increase of the initial temperature. It decreases as the feed ratio increases, while the microscopic grain size uniformity decreases.