Method and system for controlling the folding and the lack of material defects of the spinning rib of a cross-ribbed cylinder

Abstract

The application provides a spinning rib body folding and meat defect control method and system for a cross inner rib cylinder, comprising the following steps: S1, adopting multi-roller collaborative spinning; S2, establishing a finite element simulation model based on an actual core mold, a blank and a spinning roller; S3, adjusting the corner angle distribution and radial offset distribution of the spinning rollers in the spinning roller group in a power reduction mode to reduce the folding and meat defect in the finite element simulation; S4, if the folding and meat defect is not eliminated, further eliminating the folding and meat defect by increasing the attack angle of the spinning roller group; and S5, performing a process test based on the spinning parameters used in the simulation. The spinning rib body defect control method provided by the application can effectively inhibit the generation of the folding and meat defect of the cylinder spinning inner rib, and improve the size accuracy of the cylinder.

Description

Technical Field

[0001] This invention relates to the field of spinning technology, specifically to a method and system for controlling folding and missing material defects in the spinning ribbed of a cross-ribbed cylinder. Background Technology

[0002] Cross-ribbed cylindrical components are widely used in aerospace vehicles as a lightweight structure. Spin forming is an advanced near-net-shape forming technology that is expected to replace traditional milling and welding processes, further improving the lightweight level and dimensional accuracy of cross-ribbed cylindrical components.

[0003] The forming quality of the internal ribs is a key concern in the spin forming of this part. Existing spin forming methods for ribbed cylindrical parts primarily employ a two-roller process to ensure balanced spinning force. To ensure all internal ribs are fully filled, a larger downward pressure is typically used to increase the radial flow of material into the rib grooves. Due to the complex structure of the internal ribs and uneven material flow, folds and missing material defects occur at the intersections of the internal ribs, such as… Figure 1 As shown, adjusting spinning process parameters, such as the radius of the spinning wheel, the amount of pressure applied, the feed ratio, and the forming temperature, cannot resolve this type of spinning defect. This defect affects the load-bearing performance of the cross-ribbed cylindrical body, hindering the application of spinning technology in such cross-ribbed cylindrical components.

[0004] Patent document CN108161347B discloses a method for spinning a cylindrical part with an inwardly reinforcing ring. The method includes the following steps: 1. Manufacturing a simple spinning blank using plate welding or extrusion machining, leaving a process ring approximately 6mm thick and 12mm larger in diameter than the blank's outer diameter on the blank's end face; 2. Eliminating internal stress in the blank through annealing; 3. Fixing the blank in a mold using a pressure ring, and achieving forward spinning of the material by appropriately selecting parameters such as the roller pressing amount and feed speed, gradually thinning and elongating the blank. During this process, the reinforcing rib is formed by adjusting the gap between the roller and the spinning mold; 4. Removing the excess length by turning, ensuring the spun semi-finished product meets the required length. However, this invention does not suppress the folding of the internal ribs and defects caused by insufficient material during the spinning process. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a method and system for controlling folding and missing material defects in the spun ribs of cross-ribbed cylinders.

[0006] A method for controlling folding and missing material defects in the spun ribbed body of a cross-ribbed cylinder according to the present invention includes:

[0007] Step S1: Employ multi-rotor synergistic spinning;

[0008] Step S2: Establish a finite element simulation model based on the actual core mold, blank, and spinning wheel;

[0009] Step S3: Adjust the fillet distribution and radial offset distribution of the inner wheel assembly according to the power-reduction method to reduce folding and missing defects in the finite element simulation;

[0010] Step S4: If the folding and missing parts defects are not eliminated, further eliminate the folding and missing parts defects by increasing the angle of attack of the spinning wheel assembly;

[0011] Step S5: Based on the spinning parameters used in the simulation, conduct process experiments.

[0012] Preferably, in step S1:

[0013] The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

[0014] Preferably, in step S2:

[0015] The blank is meshed at the intersection of longitudinal and transverse ribs, with a mesh size of less than 0.25 mm.

[0016] Preferably, in step S3:

[0017] All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°;

[0018] The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

[0019] Preferably, in step S4:

[0020] Increase the angle of attack of each wheel in the wheel assembly, and increase the angle of attack of the rear wheel to 30° to 35°.

[0021] A control system for folding and missing material defects in the spun ribbed body of a cross-ribbed cylinder, provided by the present invention, includes:

[0022] Module M1: Employs multi-rotor coordinated spinning;

[0023] Module M2: Establishes a finite element simulation model based on the actual core mold, blank, and spinning wheel;

[0024] Module M3: Adjusts the fillet distribution and radial offset distribution of the internal spinning wheel group according to the power-reduction method to reduce folding and missing defects in finite element simulation;

[0025] Module M4: If the folding and missing parts defects are not eliminated, further eliminate the folding and missing parts defects by increasing the angle of attack of the spinning wheel group;

[0026] Module M5: Conduct process experiments based on the spinning parameters used in the simulation.

[0027] Preferably, in module M1:

[0028] The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

[0029] Preferably, in module M2:

[0030] The blank is meshed at the intersection of longitudinal and transverse ribs, with a mesh size of less than 0.25 mm.

[0031] Preferably, in module M3:

[0032] All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°;

[0033] The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

[0034] Preferably, in module M4:

[0035] Increase the angle of attack of each wheel in the wheel assembly, and increase the angle of attack of the rear wheel to 30° to 35°.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] 1. The spinning rib defect control method provided by the present invention can effectively suppress the generation of folding and missing material defects in the spinning inner ribs of the cylinder, while improving the dimensional accuracy of the cylinder;

[0038] 2. The finite element method used in this invention can reduce trial and error costs and improve economic efficiency. Attached Figure Description

[0039] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0040] Figure 1 A schematic diagram showing missing or folded defects at the intersection of longitudinal and transverse internal ribs;

[0041] Figure 2 Simulation results of missing material and folding defects at the intersection of longitudinal and transverse internal ribs;

[0042] Figure 3 A schematic diagram of coordinated spinning of three spinning wheels;

[0043] Figure 4 A simulation diagram of the intersection of longitudinal and transverse inner reinforcement bars with an axial offset of 10mm.

[0044] Figure 5A simulation diagram of the intersection of the longitudinal and transverse inner ribs at a 30° angle of attack of the rotating wheel;

[0045] Figure 6 This is a schematic diagram of the intersection of longitudinal and transverse internal reinforcement bars after the process test;

[0046] Among them, 1 is the core mold; 2 is the cylindrical blank; 3 is the first rotating wheel; 4 is the second rotating wheel; and 5 is the third rotating wheel. Detailed Implementation

[0047] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0048] Example 1:

[0049] This invention provides a process for controlling folding and missing material defects in the spun internal ribs of cylindrical bodies with longitudinal and transverse internal ribs. It employs multi-rotor collaborative spinning; establishes a finite element simulation model based on the actual mandrel, blank, and rotors; adjusts the distribution of rotor radius (r) and radial offset (Δ) within the rotor group to reduce or eliminate folding and missing material defects in the finite element simulation; if these defects still exist, the rotor angle of attack (α) is increased to further reduce folding and missing material defects; after the defects are resolved in the finite element simulation, spinning process experiments are conducted based on the spinning parameters used in the simulation. This invention can effectively suppress the generation of folding and missing material defects in spun internal ribs of cylindrical bodies with intersecting internal ribs.

[0050] The present invention provides a method for controlling the folding and missing-meat defects of the spun ribs in a cross-ribbed cylinder, such as... Figures 1-6 As shown, it includes:

[0051] Step S1: Employ multi-rotor synergistic spinning;

[0052] Specifically, in step S1:

[0053] The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

[0054] Step S2: Establish a finite element simulation model based on the actual core mold, blank, and spinning wheel;

[0055] Specifically, in step S2:

[0056] The blank is meshed at the intersection of longitudinal and transverse ribs, with a mesh size of less than 0.25 mm.

[0057] Step S3: Adjust the fillet distribution and radial offset distribution of the inner wheel assembly according to the power-reduction method to reduce folding and missing defects in the finite element simulation;

[0058] Specifically, in step S3:

[0059] All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°;

[0060] The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

[0061] Step S4: If the folding and missing parts defects are not eliminated, further eliminate the folding and missing parts defects by increasing the angle of attack of the spinning wheel assembly;

[0062] Specifically, in step S4:

[0063] Increase the angle of attack of each wheel in the wheel assembly, and increase the angle of attack of the rear wheel to 30° to 35°.

[0064] Step S5: Based on the spinning parameters used in the simulation, conduct process experiments.

[0065] Example 2:

[0066] Example 2 is a preferred embodiment of Example 1, and is used to illustrate the present invention in more detail.

[0067] This invention also provides a control system for folding and missing meat defects in the spun ribs of a cross-ribbed cylinder. The control system for folding and missing meat defects in the spun ribs of a cross-ribbed cylinder can be implemented by executing the process steps of the method for controlling folding and missing meat defects in the spun ribs of a cross-ribbed cylinder. That is, those skilled in the art can understand the method for controlling folding and missing meat defects in the spun ribs of a cross-ribbed cylinder as a preferred embodiment of the control system for folding and missing meat defects in the spun ribs of a cross-ribbed cylinder.

[0068] A control system for folding and missing material defects in the spun ribbed body of a cross-ribbed cylinder, provided by the present invention, includes:

[0069] Module M1: Employs multi-rotor coordinated spinning;

[0070] Specifically, in module M1:

[0071] The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

[0072] Module M2: Establishes a finite element simulation model based on the actual core mold, blank, and spinning wheel;

[0073] Specifically, in module M2:

[0074] The blank is meshed at the intersection of longitudinal and transverse ribs, with a mesh size of less than 0.25 mm.

[0075] Module M3: Adjusts the fillet distribution and radial offset distribution of the internal spinning wheel group according to the power-reduction method to reduce folding and missing defects in finite element simulation;

[0076] Specifically, in module M3:

[0077] All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°;

[0078] The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

[0079] Module M4: If the folding and missing parts defects are not eliminated, the folding and missing parts defects are further eliminated by rotating the wheel of the wheel assembly at an angle of attack;

[0080] Specifically, in module M4:

[0081] Increase the angle of attack of each wheel in the wheel assembly, increasing the angle of attack of the rear wheel to 30° to 35°.

[0082] Module M5: Conduct process experiments based on the spinning parameters used in the simulation.

[0083] Example 3:

[0084] Example 3 is a preferred example of Example 1, and is used to illustrate the present invention in more detail.

[0085] The purpose of this invention is to provide a method for controlling rib folding and missing material defects in spun cross-ribbed cylinders. By coordinating the control of material flow through multiple spinning wheels, the method solves the rib folding and missing material quality defects that occur in spun cross-ribbed cylinders under large downward pressure conditions, thereby improving the spun forming quality of spun cross-ribbed cylinders.

[0086] The design concept of this invention is:

[0087] The folding at the intersection of intersecting internal reinforcing bars is caused by excessive material flowing into the reinforcing bar grooves, resulting in both circumferential and axial material flows at the intersection, thus forming a fold. Insufficient fill is related to the formation of folds; material flowing away along the longitudinal reinforcing bar grooves at the intersection leads to insufficient filling of the transverse reinforcing bars, resulting in insufficient fill.

[0088] The key to solving the above two defects is to limit excessive material flow in both the circumferential and axial directions. By using more rollers and reducing the deformation distribution of each roller, the material flow in both the circumferential and axial directions is limited, resulting in more uniform material filling into the grooves.

[0089] Increasing the angle of attack α of the swivel wheel can cause more material to gather in front of the swivel wheel without filling the ribs, reducing the flow of material into the groove and decreasing the tendency for both circumferential and axial material flow.

[0090] Before implementing process control, the part at the intersection of internal ribs and the simulation results are as follows: Figure 1 and Figure 2 As shown.

[0091] The process for controlling folding and missing material defects in the spin-formed cylindrical body with longitudinal and transverse internal ribs in this invention is as follows:

[0092] (1) A three-wheel spinning process is adopted, such as Figure 3 As shown;

[0093] (2) A finite element simulation model was established based on the longitudinal and transverse internal ribbed cylinder;

[0094] (3) All wheel fillets are set in descending powers, namely R10, R8, and R6, with an angle of attack of 20° for each wheel assembly; the total radial downward pressure is Δ = 6 mm, and the radial misalignment within the wheel assembly is distributed in descending powers, i.e., Δ1 = 3 mm, Δ2 = 2 mm, and Δ3 = 1 mm, while the axial misalignment of the wheels is distributed equally, a12 = a23 = 10 mm. For example... Figure 4 The simulation results show that the folding and missing parts of the spun ribs have been improved, but not completely eliminated;

[0095] (4) The angle of attack of each wheel in the wheel assembly is increased to 30°. The simulation results are as follows: Figure 5 As shown, the folds and missing parts of the spinned ribs are completely eliminated;

[0096] (5) Based on the spinning parameters used in the spinning simulation, spinning process experiments were conducted, and the defects of rib folding and missing material at the intersection of the longitudinal and transverse internal ribs of the aluminum alloy cylinder were resolved, such as... Figure 6 As shown.

[0097] In the above technical solution (2), the cylindrical blank is meshed at the intersection of the longitudinal and transverse ribs, and the mesh size is less than 0.25mm.

[0098] The results of the embodiments show that the multi-rotor collaborative control method proposed in this invention can effectively control the folding and missing material defects at the intersection of the inner ribs during the spinning forming of cross-ribbed cylindrical parts, which is of great significance for the overall manufacturing and spinning process design of inner ribbed cylindrical parts.

[0099] Those skilled in the art will understand that, in addition to implementing the system, apparatus, and their modules provided by this invention in purely computer-readable program code, the same program can be implemented in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers by logically programming the method steps. Therefore, the system, apparatus, and their modules provided by this invention can be considered a hardware component, and the modules included therein for implementing various programs can also be considered structures within the hardware component; alternatively, modules for implementing various functions can be considered both software programs implementing the method and structures within the hardware component.

[0100] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A method for controlling folding and missing material defects in the spun ribs of a cross-ribbed cylindrical body, characterized in that, include: Step S1: Employ multi-rotor synergistic spinning; Step S2: Establish a finite element simulation model based on the actual core mold, blank, and spinning wheel; Step S3: Adjust the fillet distribution and radial offset distribution of the inner wheel assembly according to the power-reduction method to reduce folding and missing defects in the finite element simulation; Step S4: If the folding and missing parts defects are not eliminated, further eliminate the folding and missing parts defects by increasing the angle of attack of the spinning wheel assembly; Step S5: Based on the spinning parameters used in the simulation, conduct process experiments.

2. The method for controlling folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 1, characterized in that, In step S1: The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

3. The method for controlling folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 1, characterized in that, In step S2: The blank is meshed at the intersection of longitudinal and transverse ribs, with the mesh size being less than 0.25 mm.

4. The method for controlling folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 1, characterized in that, In step S3: All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°; The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

5. The method for controlling folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 1, characterized in that, In step S4: Increase the angle of attack of each wheel in the wheel assembly, and increase the angle of attack of the rear wheel to 30° to 35°.

6. A control system for folding and missing material defects in spun ribs of cross-ribbed cylindrical bodies, characterized in that, include: Module M1: Employs multi-rotor coordinated spinning; Module M2: Establishes a finite element simulation model based on the actual core mold, blank, and spinning wheel; Module M3: Adjusts the fillet distribution and radial offset distribution of the internal spinning wheel group according to the power-reduction method to reduce folding and missing defects in finite element simulation; Module M4: If the folding and missing parts defects are not eliminated, further eliminate the folding and missing parts defects by increasing the angle of attack of the spinning wheel group; Module M5: Conduct process experiments based on the spinning parameters used in the simulation.

7. The control system for folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 6, characterized in that, In module M1: The number of rotating wheels is greater than or equal to three, and the number is selected based on the equipment capacity and the amount of downward pressure.

8. The control system for folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 6, characterized in that, In module M2: The blank is meshed at the intersection of longitudinal and transverse ribs, with a mesh size of less than 0.25 mm.

9. The control system for folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 6, characterized in that, In module M3: All the rounded corners of the rotating wheels are set in descending power, and the angle of attack of their rotating wheel groups is the same, ranging from 15° to 22°; The radial misalignment within the swivel assembly is distributed in descending powers, while the axial misalignment of the swivels is distributed in equal amounts.

10. The control system for folding and missing material defects in the spun ribbed body of the cross-ribbed cylinder according to claim 6, characterized in that, In module M4: Increase the angle of attack of each wheel in the wheel assembly, and increase the angle of attack of the rear wheel to 30° to 35°.

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