Analysis of Spinning Forming Process for Thin-walled Cylinders with Cross Ribs of 2195 Aluminum-lithium Alloy

MENG Jiajie; XU Chen; TU Yujie; SHI Wenzhan; WANG Wei; ZHOU Xianjun; YU Zhongqi; PENG Heli

doi:10.3969/j.issn.1674-6457.2025.12.010

PDF(2652 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (12) : 95-103. DOI: 10.3969/j.issn.1674-6457.2025.12.010

Advanced Aerospace Manufacturing Technology

Analysis of Spinning Forming Process for Thin-walled Cylinders with Cross Ribs of 2195 Aluminum-lithium Alloy

MENG Jiajie¹, XU Chen¹, TU Yujie¹, SHI Wenzhan¹, WANG Wei¹, ZHOU Xianjun¹, YU Zhongqi², PENG Heli^1,*

Author information +

History +

Abstract

The work aims to analyze the effect of key process parameters of spinning forming on the rib filling fullness of 2195 aluminum-lithium (Al-Li) alloy to solve the problem that it is difficult to achieve sufficient material filling in the ribs during the spinning forming of thin-walled cylinders with cross ribs of 2195 Al-Li alloy due to insufficient material flowability, which affects the overall performance of cylinders. Based on the finite element simulation method, key process parameters of spinning forming were analyzed from the characteristic cross-sectional positions of typical ribs in cylinders. Taking the rib height after spinning forming as the indicator of the filling fullness of ribs in cylinders of cross ribs after forming, the influences of three process parameters, namely spinning temperature, feed ratio, and the distribution method of radial offset of the spinning wheel, on the fullness of thin-walled cylinders with cross ribs of 2195 Al-Li alloy were analyzed. The results show that the spinning temperature had little influence on the ribs height. However, increasing the temperature was beneficial to reducing the elastic modulus, strength and structural rigidity of the material, decreasing the springback after spinning and improving the fittability and forming precision. With the increase of the spinning feed ratio, the rib filling fullness first increased and then decreased. When the spinning feed ratio was in the range of 2-4 mm/r, the rib filling fullness was better. It was beneficial for rib filling fullness to adopt the average distribution method for the stepped amount of the radial. Based on the process parameters obtained from the simulation analysis in this paper, scaled and full-scale samples of thin-walled cylinder with cross ribs of 2195 Al-Li alloy with diameters of 200 mm and 550 mm and high dimensional accuracy are formed.

Key words

2195 Al-Li alloy / thin-walled cylinders with cross ribs / flow spinning forming / rib filling fullness / finite element simulation

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

MENG Jiajie, XU Chen, TU Yujie, SHI Wenzhan, WANG Wei, ZHOU Xianjun, YU Zhongqi, PENG Heli. Analysis of Spinning Forming Process for Thin-walled Cylinders with Cross Ribs of 2195 Aluminum-lithium Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(12): 95-103 https://doi.org/10.3969/j.issn.1674-6457.2025.12.010

References

[1] PRASAD N E, GOKHALE A A, RAO P R.Aluminum-Lithium Alloys: Processing, Properties, and Applications[M]. Amsterdam: Elsevier, 2014: 221-249.
[2] 廖文和, 戴宁. 航空航天结构轻量化设计制造技术发展现状与挑战[J]. 南京航空航天大学学报, 2023, 55(3): 347-360.
LIAO W H, DAI N.Development and Challenge of Lightweight Design and Manufacturing Technology for Aerospace Structures[J]. Journal of Nanjing University of Aeronautics & Astronautics, 2023, 55(3): 347-360.
[3] 张卫红, 唐长红. 航空航天装备的轻量化: 挑战与未来[J]. 航空学报, 2024, 45(5): 529965.
ZHANG W H, TANG C H.Lightweighting of Aerospace and Aeronautical Equipment: Challenges and Perspectives[J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(5): 529965.
[4] 黄晓敏, 管奔, 臧勇. 航空铝锂合金热成形研究进展[J]. 稀有金属材料与工程, 2022, 51(12): 4745-4756.
HUANG X M, GUAN B, ZANG Y.Research Process on Thermal Formability of Al-Li Alloys for Aeronautic Industry[J]. Rare Metal Materials and Engineering, 2022, 51(12): 4745-4756.
[5] RIOJA R J, LIU J.The Evolution of Al-Li Base Products for Aerospace and Space Applications[J]. Metallurgical and Materials Transactions A, 2012, 43(9): 3325-3337.
[6] 刘志鹏, 肖阳, 马凯杰, 等. 航空航天铝锂合金开发及其研究进展[J]. 材料热处理学报, 2023, 44(11): 8-17.
LIU Z P, XIAO Y, MA K J, et al.Development and Research Progress of Aerospace Al-Li Alloys[J]. Transactions of Materials and Heat Treatment, 2023, 44(11): 8-17.
[7] SAJI S, HORI S.Mechanical Properties of Aluminum Alloy at very Low Temperature[J]. Journal of Japan Institute of Light Metals, 1989, 39(8): 574-583.
[8] 吴秀亮, 刘铭, 臧金鑫, 等. 铝锂合金研究进展和航空航天应用[J]. 材料导报, 2016, 30(S2): 571-578.
WU X L, LIU M, ZANG J X, et al.Research Progress and Aerospace Application of Al-Li Alloy[J]. Materials Reports, 2016, 30(S2): 571-578.
[9] DURSUN T, SOUTIS C.Recent Developments in Advanced Aircraft Aluminium Alloys[J]. Materials & Design (1980-2015), 2014, 56: 862-871.
[10] 邓名洋, 李瑞金, 王硕, 等. 铝锂合金热处理工艺及其对材料性能影响研究现状[J]. 有色金属加工, 2023, 52(4): 17-25.
DENG M Y, LI R J, WANG S, et al.Study on Heat Treatment Process and Its Effect on Material Properties of Al-Li Alloy[J]. Nonferrous Metals Processing, 2023, 52(4): 17-25.
[11] 曹安斋. 铝合金内腔带筋筒形挤压件成形工艺分析与实验研究[D]. 太原: 中北大学, 2008.
CAO A Z.The Technology Analysis and Experimental Research on Round Extrusion Part with Intra-cavity Rib Forming of Aluminum Alloy[D]. Taiyuan: North University of China, 2008.
[12] 宋春丽, 裴小龙, 陈利文, 等. 大型薄壁复杂铝合金舱体件低压铸造模拟对比分析[J]. 特种铸造及有色合金, 2023, 43(6): 794-799.
SONG C L, PEI X L, CHEN L W, et al.Comparison Analysis of Low Pressure Casting Simulation of Large Thin-Wall Complex Aluminum Alloy Cabin[J]. Special Casting & Nonferrous Alloys, 2023, 43(6): 794-799.
[13] 申世军, 陆皓, 倪勇军, 等. 2219铝合金网格壁板增量成形有限元仿真[J]. 塑性工程学报, 2014, 21(2): 71-75.
SHEN S J, LU H, NI Y J, et al.Finite Element Simulation of Incremental Forming for 2219 Aluminium Integrally Stiffened Panel[J]. Journal of Plasticity Engineering, 2014, 21(2): 71-75.
[14] 孟佳杰, 徐晨, 徐琅, 等. 含凸台铝合金壁板垫板压弯成形规律分析[J]. 上海航天(中英文), 2024, 41(S2): 22-30.
MENG J J, XU C, XU L, et al.Analysis of Bending Forming Law of Aluminum Alloy Wall Plate with Boss[J]. Aerospace Shanghai (Chinese & English), 2024, 41(S2): 22-30.
[15] 于忠奇, 王凤琪, 戴冬华, 等. 带筋薄壁筒体类构件流动旋压技术研究进展[J]. 塑性工程学报, 2021, 28(8): 1-10.
YU Z Q, WANG F Q, DAI D H, et al.A Review of Flow Spinning Technology of Stiffened Thin-Walled Cylinders[J]. Journal of Plasticity Engineering, 2021, 28(8): 1-10.
[16] MARINI D, CUNNINGHAM D, XIROUCHAKIS P, et al.Flow Forming: A Review of Research Methodologies, Prediction Models and Their Applications[J]. International Journal of Mechanical Engineering and Technology, 2016, 7(5): 285-315.
[17] 曾祥. 铝合金纵横内筋筒形件流动旋压成形与组织演变研究[D]. 西安: 西北工业大学, 2021.
ZENG X.Study on Flow Spinning Forming and Microstructure Evolution of Aluminum Alloy Tubular Part with Longitudinal and Transverse Inner Ribs[D]. Xi’an: Northwestern Polytechnical University, 2021.
[18] ZHAN M, YANG H, GUO J, et al.Review on Hot Spinning for Difficult-to-Deform Lightweight Metals[J]. Transactions of Nonferrous Metals Society of China, 2015, 25(6): 1732-1743.
[19] 李晓凯. 带内筋筒形件超声辅助旋压实验与仿真研究[D]. 上海: 上海交通大学, 2020.
LI X K.Experiment and Simulation Study on Inner Ribbed Cylindrical Parts Spinning with Ultrasonic Vibration[D]. Shanghai: Shanghai Jiao Tong University, 2020.
[20] 周敏, 杜勇, 曾权, 等. 带横向内筋张紧轮旋压成形分析[J]. 精密成形工程, 2015, 7(2): 66-70.
ZHOU M, DU Y, ZENG Q, et al.Spinning Forming Analysis of Tension Wheel with Transverse Inner Ribs[J]. Journal of Netshape Forming Engineering, 2015, 7(2): 66-70.
[21] JIANG S Y, ZHENG Y F, REN Z Y, et al.Multi-Pass Spinning of Thin-Walled Tubular Part with Longitudinal Inner Ribs[J]. Transactions of Nonferrous Metals Society of China, 2009, 19(1): 215-221.
[22] ABD-ELTWAB A A, EL-ABDEN S Z, AHMED K I E, et al. An Investigation into Forming Internally-Spline Sleeves by Ball Spinning[J]. International Journal of Mechanical Sciences, 2017, 134: 399-410.
[23] 写旭, 韩冬, 尚勇, 等. 带环向内筋筒形件旋压成形工艺试验及缺陷分析[J]. 航天制造技术, 2022(5): 62-65.
XIE X, HAN D, SHANG Y, et al.Spinning Process Test and Defect Analysis of Cylindrical Parts with Circumferential Inner Ribs[J]. Aerospace Manufacturing Technology, 2022(5): 62-65.
[24] 朱恩锐, 崔霞, 郭陆陆, 等. TB6钛合金筒形件强力旋压成形工艺模拟[J]. 锻压技术, 2023, 48(2): 126-134.
ZHU E R, CUI X, GUO L L, et al.Simulation on Power Spinning Process for TB6 Titanium Alloy Cylindrical Parts[J]. Forging & Stamping Technology, 2023, 48(2): 126-134.
[25] LYU W, ZHAN M, GAO P F, et al.Rib Filling Behavior in Flow Forming of Thin-Walled Tube with Helical Grid-Stiffened Ribs[J]. The International Journal of Advanced Manufacturing Technology, 2022, 119(5): 2877-2894.