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Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process

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Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process Durham E-Theses Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process WANG, LIN How to cite: WANG, LIN (2012) Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process, Durham theses, Durham University. Available at Durham E-Theses Online: http://etheses.dur.ac.uk/3537/ Use policy The full-text may be used and/or reproduced, and given to third parties in any format or medium, without prior permission or charge, for personal research or study, educational, or not-for-prot purposes provided that: • a full bibliographic reference is made to the original source • a link is made to the metadata record in Durham E-Theses • the full-text is not changed in any way The full-text must not be sold in any format or medium without the formal permission of the copyright holders. Please consult the full Durham E-Theses policy for further details. Academic Support Oce, Durham University, University Oce, Old Elvet, Durham DH1 3HP e-mail: [email protected] Tel: +44 0191 334 6107 http://etheses.dur.ac.uk 2 Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process Lin Wang Doctor of Philosophy School of Engineering and Computing Sciences Durham University 2012 Analysis of Material Deformation and Wrinkling Failure in Conventional Metal Spinning Process Lin Wang Abstract Sheet metal spinning is one of the metal forming processes, where a flat metal blank is rotated at a high speed and formed into an axisymmetric part by a roller which gradually forces the blank onto a mandrel, bearing the final shape of the spun part. Over the last few decades, sheet metal spinning has developed significantly and spun products have been widely used in various industries. Although the spinning process has already been known for centuries, the process design still highly relies on experienced spinners using trial-and-error. Challenges remain to achieve high product dimensional accuracy and prevent material failures. This PhD project aims to gain insight into the material deformation and wrinkling failure mechanics in the conventional spinning process by employing experimental and numerical methods. In this study, a tool compensation technique has been proposed and used to develop CNC multiple roller path (passes). 3-D elastic-plastic Finite Element (FE) models have been developed to analyse the material deformation and wrinkling failure of the spinning process. By combining these two techniques in the process design, the time and materials wasted by using the trial-and-error could be decreased significantly. In addition, it may provide a practical approach of standardised operation for the spinning industry and thus improve the product quality, process repeatability and production efficiency. Furthermore, effects of process parameters, e.g. roller path profiles, feed rate and spindle speed, on the variations of tool forces, stresses, strains, wall thickness and wrinkling failures have also been investigated. Using a concave roller path produces high tool forces, stresses and reduction of wall thickness. Conversely, low tool forces, stresses and wall thinning have been obtained in the FE model which uses the convex roller path. High feed ratios help to maintain original blank thickness but also lead to material failures and rough surface finish. Thus it is necessary to find a “trade off” feed ratio for a spinning process design. i Declaration I hereby declare that this thesis is my own work, which is based on research carried out in the School of Engineering and Computing Sciences, Durham University, UK. No portion of the work in the thesis has been submitted in support of an application for another degree or qualification of any other university or institute of learning. Copyright © 2012 by Lin Wang The copyright of this thesis rests with the author. No quotation from it should be published without the prior written consent and information derived from it should be acknowledged. ii Acknowledgements My deepest gratitude goes first and foremost to my supervisor, Dr. Hui Long, for her constant encouragement and guidance through all the stages of my PhD research and thesis writing. Her tremendous effort and tireless support made this work possible and was critical to the successful completion of this thesis. Secondly, I would like to acknowledge the consistent support and valuable advice from Mr. David Ashley, Mr. Martyn Roberts, Mr. Peter White, Mr. Fred Hoye, Mr. Paul Johnson, and Mr. Kris Carter of Metal Spinners Group Ltd, where I worked as a KTP associate for two years. I appreciate the contribution to this research by former students of Durham University, Mr. Seth Hamilton, Mr. Stephen Pell, and Mr. Paul Jagger for their suggestion and assistance on FE modelling and the experimental design of metal spinning. My sincere thanks also go to Miss. Rachel Ashworth for sharing literatures and discussing theoretical analysis of the metal spinning process. I gratefully acknowledge Dr. Xiaoying Zhuang and Mr. Xing Tan for their precious advice on the thesis writing. Finally, I should like to express my heartfelt gratitude to my beloved parents. This thesis is by all means devoted to them because they have assisted, supported and cared for me all of my life. The first two years of this PhD study were financially supported by UK Technology Strategy Board and Metal Spinners Group Ltd, Project No. 6590. The final year of study was sponsored by School of Engineering and Computing Sciences, Durham University. iii Publications Aspects of the work presented in this thesis have been published in the following journal papers and conference proceedings: 1. Wang, L., Long, H., 2011. Investigation of material deformation in multi-pass conventional metal spinning. Materials & Design, 32, 2891-2899. 2. Wang, L., Long, H., Ashley, D., Roberts, M., White, P., 2011. Effects of roller feed ratio on wrinkling failure in conventional spinning of a cylindrical cup. Proceedings of IMechE: Part B: Journal of Engineering Manufacture, 225, 1991-2006. 3. Wang, L., Long, H., 2011. A study of effects of roller path profiles on tool forces and part wall thickness variation in conventional metal spinning, Journal of Materials Processing Technology, 211, 2140-2151. 4. Wang, L., Long, H., Ashley, D., Roberts, M., White, P., 2010. Analysis of single-pass conventional spinning by Taguchi and Finite Element methods, Steel Research International, 81, 974-977. 5. Wang, L., Long, H., 2010. Stress analysis of multi-pass conventional spinning, Proc. of 8th International Conference on Manufacturing Research, Durham, UK. 6. Wang, L., Long, H., 2011. Investigation of Effects of Roller Path Profiles on Wrinkling in Conventional Spinning, Proc. of 10th International Conference on Technology of Plasticity, Aachen, Germany. 7. Long, H., Wang, L., Jagger, P., 2011. Roller Force Analysis in Multi-pass Conventional Spinning by Finite Element Simulation and Experimental Measurement, Proc. of 10th International Conference on Technology of Plasticity, Aachen, Germany. iv Table of Contents Abstract ............................................................................................................................i Declaration ......................................................................................................................ii Acknowledgements ........................................................................................................iii Publications ....................................................................................................................iv Table of Contents.............................................................................................................v List of Figures............................................................................................................... viii List of Tables....................................................................................................................x List of Abbreviations .......................................................................................................xi Nomenclature ................................................................................................................xii Terminology in Spinning ...............................................................................................xvi 1. Introduction .............................................................................................................. 1 1.1 Background........................................................................................................... 1 1.2 Scope of Research ............................................................................................... 5 1.3 Structure of Thesis ................................................................................................ 8 2. Literature Review ................................................................................................... 10 2.1 Investigation Techniques..................................................................................... 10 2.1.1 Theoretical Study.......................................................................................... 10 2.1.1.1 Analysis of Tool Forces .......................................................................... 10 2.1.1.2 Prediction of Strains ................................................................................11 2.1.1.3 Investigation of Wrinkling Failures ..........................................................11
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