Research on Mechanism of Current-assisted Flow-splitting Spinning for the Complex Component Made of Difficult-to-deform Metal
Aiming at the problems of long manufacturing cycle time and low toughness of complex components made of difficult-to-deform manufactured by traditional multi-pass cutting and gear shaping method,a current-assisted flow-splitting spinning(CAFSS)is proposed to realize the manufacture for the complex component with less or no chips.The principle of CAFSS of complex 30CrMnSiA alloy structural steel components with"different wall thickness"and"different structure"is analyzed.A finite element model of CAFSS is established using ABAQUS software,and its accuracy is verified.The mechanism of CAFSS is analyzed and an experiment of the CAFSS is carried out.The results show that the FE model has high prediction accuracy for the CAFSS with maximum relative errors of only 6.72%and 5.63%for flow spinning and splitting spinning,respectively.The material of current-assisted flow spinning(CAFS)presents a three-direction compressive stress state.At the end stage of the CAFS,there will be large tensile stress and tensile strain in the wall section of the cup-shaped part.During the current-assisted splitting spinning(CASS),the stress distribution shows the three-direction compressive stress at the tooth groove area.However,at the top of the tooth,it is the tensile stress in the radial direction and the other two directions are the compressive stress.The pulsed current reduces the material deformation resistance,which not only reduces the danger zone of the deformation area during flow spinning,but also improves the ability of the material to fill in the radial direction during splitting-spinning,which in turn reduces the phenomenon of tooth unfilling.The experimental results show that the CAFSS can achieve high-precision high-strength and toughness preparation of difficult-to-deform complex components.
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