Finite Element Method Simulation of  Stagger Power Spinning Forming of Automobile Spoke

Abstract

Abstract:

Abstract： In order to make an indepth research on stagger spinning process of automobile spoke with three rollers, the elasticplastic finite element simulation model was established and the forming process was analyzed based on ABAQUS. The methods for imposing boundary conditions and trajectory curves of rollers were introduced. The correctness of the simulation model was verified by calculating the ratios of kinetic energy and pseudo strain energy to internal energy and by comparing simulation results with production parts by using the reverse technique and experimental measurement. The results show that the material does not produce plastic deformation in the central area of the blank contacting with tailstock. Plastic deformation distributes homogeneously in the circumferential direction of the spoke and changes in the radial direction. Thus equivalent plastic strain rings and thickness rings are formed. Plastic deformation is severe when forming curved fillet areas and outer edge regions of the spoke. Material accumulation defect is likely to occur when forming outer edge regions of the spoke. The thickness of the spoke is different along the generatrix direction, and it changes in accordance with the sine law.

Key words: automobile spoke, stagger spinning, forming, finite element method (FEM) simulation

CLC Number:

TG 306

LU Ping1a,1b,ZHANG Yunkai1a,1b,CHEN Bo2. Finite Element Method Simulation of Stagger Power Spinning Forming of Automobile Spoke[J]. Journal of Shanghai Jiaotong University, 2015, 49(01): 56-61.

References

［1］张治民, 王强, 路光, 等. 重型车辆铝合金轮辋挤压成形技术及应用［J］. 机械工程学报, 2012, 48(18): 5559.

ZHANG Zhimin, WANG Qiang, LU Guang, et al. Research on extrusion technology and application for aluminum alloy wheel rim of heavy vehicles ［J］. Journal of Mechanical Engineering, 2012, 48(18): 5559.

［2］王慧玲. 轮辋滚压过程仿真与成形工艺研究［D］. 上海交通大学机械与动力工程学院, 2009.

［3］杨合, 詹梅, 李甜, 等. 铝合金大型复杂薄壁壳体旋压研究进展［J］. 中国有色金属学报, 2011, 21(10): 25342550.

YANG He, ZHAN Mei, LI Tian, et al. Advances in spinning of aluminum alloy largesized complicated thinwalled shells ［J］. Chinese Journal of Nonferrous Metals, 2011, 21(10): 25342550.

［4］Music O, Allwood J M, Kawai K. A review of the mechanics of metal spinning ［J］. Journal of Materials Processing Technology, 2010, 210(1): 323.

［5］王彦菊, 方刚, 张剑寒, 等. 变厚度轮辐强力旋压成形过程的分析［J］. 材料科学与工艺, 2012, 20(3): 103108.

WANG Yanju, FANG Gang, ZHANG Jianhan, et al. Finite element simulation for the spinning process of an automobile spokes with varying thickness ［J］. Materials Science and Technology, 2012, 20(3): 103108.

［6］Bai Q, Yang H, Zhan M. Finite element modeling of power spinning of thinwalled shell with hoop inner rib ［J］. Transactions of Nonferrous Metals Society of China, 2008, 18(1): 613.

［7］Sebastiani G, Brosius A, Ewers R, et al. Numerical investigation on dynamic effects during sheet metal spinning by explicit finiteelementanalysis ［J］. Journal of Materials Processing Technology, 2006, 177(13): 401403.

［8］Mohebbi M S, Akbarzadeh A. Experimental study and FEM analysis of redundant strains in flow forming of tubes ［J］. Journal of Materials Processing Technology, 2010, 210(2): 38939.

［9］曾国, 来新民, 于忠奇, 等. 多道次辊弯成形数值模拟技术［J］.上海交通大学学报, 2007, 41(10): 15981602.

ZENG Guo, LAI Xinmin,YU Zhongqi, et al. The Simulation of roll forming with multiple passes［J］. Journal of Shanghai Jiaotong University, 2007, 41(10): 15981602.

［10］李玉强, 崔振山, 阮雪榆, 等. 工艺参数对多道次拉旋应力应变分布的影响规律［J］. 塑性工程学报, 2004, 11(5): 1722.

LI Yuqiang, CUI Zhenshan, RUAN Xueyu, et al. Effects of parameters on the distributions of stress and strain of multiprocess drawspinning ［J］. Journal of Plasticity Engineering, 2004, 11(5): 1722.

［11］马飞, 杨合, 詹梅. 工艺参数对平板毛坯普旋成形的影响规律［J］. 机械科学与技术, 2007, 26(3): 309313.

MA Fei, YANG He, ZHAN Mei. Influence of process parameters on conventional spinning formation process ［J］. Mechanical Science and Technology, 2007, 26(3): 309313.

［12］Wang L, Long H. Investigation of material deformation in multipass conventional metal spinning ［J］. Materials and Design, 2011, 32(5): 28912899.

［13］Chen M D, Hsu R Q, Fuh K H. Forecast of shear spinning force and surface roughness of spun cones by employing regression analysis ［J］. International Journal of Machine Tools and Manufacture, 2001, 41(12): 17211734.

［14］Sekiguchi A, Arai H. Control of wall thickness distribution by oblique shear spinning methods ［J］. Journal of Materials Processing Technology, 2012, 212(4): 786793.

［15］詹梅, 李虎, 杨合, 等. 大型复杂薄壁壳体多道次旋压过程中的壁厚变化［J］. 塑性工程学报, 2008, 15(2): 115121.

ZHAN Mei, LI Hu, YANG He, et al. Wall thickness variation during multipass spinning of large complicated shell ［J］. Journal of Plasticity Engineering, 2008, 15(2): 115121.

［16］Zoghi H, Arezoodar A F, Sayeaftabi M. Enhanced finite element analysis of material deformation and strain distribution in spinning of 42CrMo steel tubes at elevated temperature ［J］. Materials and Design, 2013, 47：234242.

[1]	TANG Genglin, LI Jianjun, LI Yuanhui, ZHANG Longyao, ZHU Wenfeng. Numerical Simulation and Experimental Research of Sheet Hemming Forming Based on Adhesive Filling [J]. Journal of Shanghai Jiao Tong University, 2022, 56(4): 523-531.
[2]	ZHENG Gaoyuan, ZHAO Yixi, CUI Junhui. Formation Law of Surface Defects in Stretch-Bending Formamtion of Aluminum Trim Strip for Automobile Body [J]. Journal of Shanghai Jiao Tong University, 2022, 56(1): 53-61.
[3]	YOU Shuman, LI Jie, ZHAO Yixi, HU Yihui. Process Parameters of Flexible Flanging [J]. Journal of Shanghai Jiao Tong University, 2021, 55(10): 1246-1254.
[4]	CHEN Xia, WEN Tong, LIU Kefan, HONG Yifei . Test of Friction Parameters in Bulk Metal Forming Based on Forward Extrusion Processes [J]. Journal of Shanghai Jiao Tong University (Science), 2020, 25(3): 333-339.
[5]	YUAN Ding,SUN Huixian,YAN Yunbin,QUAN Houde. Influence of Node Local Oscillator Errors on Distributed Transmit Beamforming [J]. Journal of Shanghai Jiaotong University, 2020, 54(1): 92-99.
[6]	LI Bing1,2,3,WANG Yongming1,3,HUANG Haining2,3. Multiple Signal Classification Beam-Forming Method Based on Time Domain Analysis [J]. Journal of Shanghai Jiaotong University, 2019, 53(8): 928-935.
[7]	LIU Yongcai,BAO Yidong,QIN Xuejiao,LIU Yulin,CHEN Wenliang. Constructions of Intermediate Configuration in Sheet Forming Simulation [J]. Journal of Shanghai Jiaotong University, 2019, 53(6): 713-718.
[8]	DU Chenyang,KONG Qingshuai,ZHAO Yixi,YU Zhongqi. Evaluation of Flange Wrinkling Prediction Methods of Conventional Spinning for Thin-Walled Spherical Components [J]. Journal of Shanghai Jiaotong University, 2019, 53(4): 431-437.
[9]	MAO Mengyun,PENG Linfa,LAI Xinmin. Experimental Study of the Grain Size Effect on Scratching Behaviors of Pure Copper [J]. Journal of Shanghai Jiaotong University, 2019, 53(3): 253-259.
[10]	QIN Feng, ZHAO Hongfeng, LIU Weipeng. Research on Short Message Data Link of Air-to-air Missile Based on Beam Alignment [J]. Air & Space Defense, 2019, 2(2): 16-22.
[11]	ZHANG Xiangkui,WANG Yang,WANG Changsheng,HU Ping. Blank Optimization for Sheet Metal Forming Using Inverse Finite Element Method and Mesh Mapping [J]. Journal of Shanghai Jiaotong University, 2019, 53(11): 1389-1394.
[12]	WANG Zimin,LIU Qi,GU Ruiying,WANG Wurong,WEI Xicheng. Formability of AZ31B Magnesium Alloy Sheet Under Different Die Temperatures [J]. Journal of Shanghai Jiaotong University, 2018, 52(9): 1092-1097.
[13]	CHEN Weiye,ZOU Tianxia,TANG Ding,GUO Feipeng,LI Dayong. Aluminum Foil Forming Limitation Test and Numerical Simulation [J]. Journal of Shanghai Jiaotong University, 2018, 52(9): 1081-1085.
[14]	XU Yong1 (徐勇), TANG Qian2 (唐倩), HOU Linzao2 (候林早), LI Mian2* (李冕). Decision Model for Market of Performing Arts with Factorization Machine [J]. Journal of Shanghai Jiao Tong University (Science), 2018, 23(1): 74-84.
[15]	WANG Lidong1,WEI Ran2,XU Peng2,ZHAO Kexin2,PENG Xiongqi1. A TemperatureDependent Hyperelastic Constitutive [J]. Journal of Shanghai Jiaotong University, 2017, 51(9): 1025-1030.

Finite Element Method Simulation of Stagger Power Spinning Forming of Automobile Spoke

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 15

Recommended Articles

Metrics

Comments