<p>Thin-walled cylindrical rings with multi-level ribs are components with different rib heights, which can improve the degree of light-weight while ensuring strength. Spinning extrusion forming processing is one of the integral forming methods for manufacturing these components. In this paper, thin-walled cylindrical rings with two-level ribs (TCRTR) are formed by spinning extrusion forming processing. Because low longitudinal ribs (LLRs) formed first will hinder the flow of skin material, the effective stress between the roller and the component will increase, causing stress concentration at LLRs and a risk of roller breakage. Hence, the two-step spin extrusion forming (TSEF) processing is proposed. In the 1st step, the initial roller is used to form a portion of high longitudinal ribs (HLRs) and the transverse rib (TR). In the 2nd step, the second roller is used to increase the height of HLRs and TR further while forming LLRs. TSEF processing helps reduce radial stress by ensuring both HLRs and LLRs reach the target height simultaneously. A quantitative criterion aligned with rib increase patterns is established, and the HLRs forming heights in the 1st step are determined through theoretical calculations and surface fitting. Besides, the material flow law at the intersection of longitudinal and transverse ribs is researched. At HLR-TR intersections, material comes from axial flow in HLRs and circumferential flow in TR, while LLR-TR intersections rely primarily on TR’s circumferential flow. Finally, experimental trials on TCRTR confirm TSEF’s effectiveness: coordinated deformation among HLRs, LLRs, and TRs enhances forming uniformity and optimizes stress distribution.</p>

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Research on the two-step method in spin extrusion forming for thin-walled cylindrical rings with two-level ribs

  • Zhengwu Zhu,
  • Yixi Zhao,
  • Yawen Ouyang,
  • Zhongqi Yu,
  • Xinghan Chen

摘要

Thin-walled cylindrical rings with multi-level ribs are components with different rib heights, which can improve the degree of light-weight while ensuring strength. Spinning extrusion forming processing is one of the integral forming methods for manufacturing these components. In this paper, thin-walled cylindrical rings with two-level ribs (TCRTR) are formed by spinning extrusion forming processing. Because low longitudinal ribs (LLRs) formed first will hinder the flow of skin material, the effective stress between the roller and the component will increase, causing stress concentration at LLRs and a risk of roller breakage. Hence, the two-step spin extrusion forming (TSEF) processing is proposed. In the 1st step, the initial roller is used to form a portion of high longitudinal ribs (HLRs) and the transverse rib (TR). In the 2nd step, the second roller is used to increase the height of HLRs and TR further while forming LLRs. TSEF processing helps reduce radial stress by ensuring both HLRs and LLRs reach the target height simultaneously. A quantitative criterion aligned with rib increase patterns is established, and the HLRs forming heights in the 1st step are determined through theoretical calculations and surface fitting. Besides, the material flow law at the intersection of longitudinal and transverse ribs is researched. At HLR-TR intersections, material comes from axial flow in HLRs and circumferential flow in TR, while LLR-TR intersections rely primarily on TR’s circumferential flow. Finally, experimental trials on TCRTR confirm TSEF’s effectiveness: coordinated deformation among HLRs, LLRs, and TRs enhances forming uniformity and optimizes stress distribution.