T-Bar Cylindrical Member Spinning for Integral Plastic Forming
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Solution Overview
Problem
Current methods for machining or block forming of high-performance, lightweight T-bar cylindrical members in aerospace components face challenges such as low material utilization, long cycle times, residual stresses, shape distortion, and high energy consumption, making it difficult to achieve integral plastic forming.
Innovation Solution
A staged shearing and forming method using a numerically controlled spinning machine with multiple spinning wheels, including shear, flow, fractal, and flat spinning wheels, to progressively form a T-bar cylindrical member by controlling the spinning wheels' contact and movement to achieve an unsaturated I-bar, saturated I-bar, Y-bar, and finally a T-bar structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If machining or block forming methods are used for T-bar cylindrical members, then high strength and lightweight properties can be achieved, but material utilization is low, cycle time is long, and residual stresses cause shape distortion
Solution Approach 1:
The forming process is divided into multiple stages with different spinning wheels (flow spinning wheel for initial forming, fractal spinning wheel for rib formation, flat spinning wheel for final shaping) to complete complex T-bar cylindrical member formation efficiently in one integral process
Solution Approach 2:
Multiple spinning operations are merged into a single integral plastic forming process, combining flow spinning, fractal spinning, and flat spinning in sequence to form the complete T-bar cylindrical member without separation into multiple manufacturing steps
2Strength
If machining or block forming methods are used, then high strength can be achieved, but material utilization is low
Solution Approach 1:
The material is progressively deformed through controlled plastic flow under varying pressure and velocity parameters during the spinning process, transforming the blank directly into the final T-bar cylindrical member shape without material removal
Solution Approach 2:
The process forms complex geometries with integrated ribs and varying wall thicknesses in a single integral piece, achieving high strength through optimized material distribution rather than material removal or assembly
3Force
If conventional spinning methods are used for cylindrical members with longitudinal ribs, then low molding load can be achieved, but high energy consumption and pollution occur
Solution Approach 1:
The spinning process is segmented into distinct stages with specialized spinning wheels for different forming tasks, allowing optimized force application at each stage and reducing overall energy consumption compared to conventional single-stage spinning
Solution Approach 2:
The process uses room temperature forming with controlled plastic flow parameters instead of high-temperature hot working, reducing energy consumption while maintaining low molding load through progressive deformation
4Manufacturing precision
If integral plastic forming is attempted for complex thin-walled T-bar cylindrical members, then high precision can be achieved, but the hard-to-form features make it very difficult
Solution Approach 1:
The complex forming process is divided into manageable stages with specialized spinning wheels for each task (flow spinning for base formation, fractal spinning for rib creation, flat spinning for final shaping), making the overall complex process easier to control and execute
Solution Approach 2:
The spinning wheels are designed with dynamic characteristics that allow them to adapt to the varying geometry during forming, with controlled material flow and pressure distribution to handle thin-walled complex features while maintaining precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances forming efficiency and reduces production costs by enabling integral plastic forming at room temperature, improving material utilization and reducing energy consumption while maintaining high precision and accuracy.
Implementation Method 1
controlling a shear working surface of a shear spinning wheel to be in contact with a surface of a cylindrical member blank; controlling a circumferential rotation of the cylindrical member blank driven by the mandrel and controlling an axial feeding of the shear spinning wheel
Implementation Method 2
controlling a working surface of a flow spinning wheel to be in perpendicular contact with a surface of the unsaturated I-bar cylindrical member; controlling the flow spinning wheel to thin one side of the unsaturated I-bar cylindrical member until a wall thickness difference on both sides satisfies a preset difference condition
Implementation Method 3
controlling a fractal working surface of a fractal spinning wheel to be in contact with a top of the saturated I-bar structure, controlling the cylindrical member blank to maintain the circumferential rotation state to control the fractal spinning wheel to perform a radial feeding movement
Implementation Method 4
controlling a working surface of a flat spinning wheel to be in perpendicular contact with a surface of the Y-bar cylindrical member, controlling the flat spinning wheel to feed radially along a top of the Y-bar to obtain a T-bar cylindrical member
Data Source
AI summary
The present disclosure provides a staged shearing and forming method for a T-bar cylindrical member, comprising: controlling a shear working surface of a shear spinning wheel in contact with a surface of a cylindrical member blank; controlling a circumferential rotation of the cylindrical member blank; controlling a working surface of a flow spinning wheel to be in perpendicular contact with a surface of the unsaturated I-bar cylindrical member and controlling the cylindrical member blank to be maintained in a circumferential rotational state; controlling the flow spinning wheel to thin one side of the unsaturated I-bar cylindrical member; controlling a fractal working surface of a fractal spinning wheel in contact with a top of the saturated I-bar structure; controlling a working surface of a flat spinning wheel to be in perpendicular contact with a surface of the Y-bar cylindrical member.