Rolling Forming Process of Thin-walled V-shaped Sealing Rings of Superalloys

WANG Tao; LIU Jing; LI Lanyun; ZHU Zheyi

doi:10.3969/j.issn.1674-6457.2026.04.017

PDF(14452 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (4) : 167-177. DOI: 10.3969/j.issn.1674-6457.2026.04.017

Superalloy Forming

Rolling Forming Process of Thin-walled V-shaped Sealing Rings of Superalloys

WANG Tao, LIU Jing^*, LI Lanyun, ZHU Zheyi

Author information +

History +

Abstract

The work aims to study the stress-strain law of thin-walled superalloys during the rolling forming of V-shaped sealing rings to address the issues of wrinkling in the forming process. A 3D elastoplastic finite element model for multi-pass rolling forming of sealing rings was established using ABAQUS software. The influence of die structure on the deformation characteristics of V-shaped superalloy sealing rings during rolling forming was systematically analyzed. Additionally, the effects of process parameters (roller diameter, mandrel rotational speed, and roller feed rate) on wrinkling, wall thickness, and outer diameter of the sealing rings were investigated via a single-factor approach. The wrinkling defect in sealing ring rolling forming was fundamentally attributed to circumferential buckling of the blank ends due to insufficient die constraints. Adding stiffening ribs to both ends of the mandrel significantly enhanced forming stability and effectively mitigated wrinkling. Roller diameter increase reduced the wall thickness thinning rate but had negligible impact on outer diameter. Mandrel rotational speed increase initially intensified then suppressed wall thickness thinning, while outer diameter remained stable. Roller feed rate increase exacerbated wall thinning and expanded outer diameter. Based on the above findings, rolling experiments are conducted using optimized process parameters (roller diameter 60 mm, mandrel rotational speed 6.3 rad/s, roller feed rate 2.1 mm/r), outer diameter deviations are within 1%, cross-sectional wall thickness deviations remain below 10%. This validates the precision forming capability of V-shaped superalloy sealing rings.

Key words

V-shaped sealing ring / superalloy / rolling forming / wrinkling / numerical simulation

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

WANG Tao, LIU Jing, LI Lanyun, ZHU Zheyi. Rolling Forming Process of Thin-walled V-shaped Sealing Rings of Superalloys[J]. Journal of Netshape Forming Engineering. 2026, 18(4): 167-177 https://doi.org/10.3969/j.issn.1674-6457.2026.04.017

References

[1] YAN B Y, MENG B, ZHU Y, et al.A Global Springback Compensation Method for Manufacturing Metallic Seal Ring with Complex Cross-Section and Submillimeter Precision[J]. Journal of Materials Processing Technology, 2024, 331: 118498.
[2] QIAO L N, KELLER C, ZENCKER U, et al.Three-Dimensional Finite Element Analysis of O-Ring Metal Seals Considering Varying Material Properties and Different Seal Diameters[J]. International Journal of Pressure Vessels and Piping, 2019, 176: 103953.
[3] CHUPP R E, HENDRICKS R C, LATTIME S B, et al.Sealing in Turbomachinery[J]. Journal of Propulsion and Power, 2006, 22(2): 313-349.
[4] YANG H, ZHAN M, LIU Y L, et al.Some Advanced Plastic Processing Technologies and Their Numerical Simulation[J]. Journal of Materials Processing Technology, 2004, 151(1/2/3): 63-69.
[5] 马尧, 冉晶. 航空发动机W型金属封严环滚压成形工艺研究[J]. 科技创新导报, 2019, 16(11): 20-22.
MA Y, RAN J.Study on Rolling Forming Technology of W-Shaped Metal Seal Ring of Aero-Engine[J]. Science and Technology Innovation Herald, 2019, 16(11): 20-22.
[6] 郭正华, 史明智, 赵刚要, 等. 超声振动对W形金属密封环滚压成形不均匀变形的影响[J]. 稀有金属材料与工程, 2024, 53(4): 1103-1110.
GUO Z H, SHI M Z, ZHAO G Y, et al.Effect of Ultrasonic Vibration on Uneven Deformation of Large Diameter Thin-Walled Superalloy W-Ring during Rolling Forming[J]. Rare Metal Materials and Engineering, 2024, 53(4): 1103-1110.
[7] 孟宝, 贺炜林, 万敏. 航空发动机金属封严环成形回弹预测与控制[J]. 锻压技术, 2021, 46(9): 145-153.
MENG B, HE W L, WAN M.Prediction and Control of Springback for Aeroengine Metallic Sealing Ring Forming[J]. Forging & Stamping Technology, 2021, 46(9): 145-153.
[8] 刘东, 付明杰, 万自永, 等. GH4169合金矩形截面环轧制曲线的实验研究[J]. 航空学报, 2007, 28(5): 1276-1280.
LIU D, FU M J, WAN Z Y, et al.Rolling Strategies in the Rolling Process of GH4169 Alloy with Rectangle Cross-Section Ring[J]. Acta Aeronautica et Astronautica Sinica, 2007, 28(5): 1276-1280.
[9] 刘恒. 某型航空发动机隔热屏滚压成形过程力学分析[D]. 阜新: 辽宁工程技术大学, 2020.
LIU H.Mechanical Analysis of the Roll Forming Process for an Aero-Engine Heat Shield[D]. Fuxin: Liaoning Technical University, 2020.
[10] ZHANG X, LI H W, ZHAN M.Mechanism for the Macro and Micro Behaviors of the Ni-Based Superalloy during Electrically-Assisted Tension: Local Joule Heating Effect[J]. Journal of Alloys and Compounds, 2018, 742: 480-489.
[11] 吴新洲, 史明智, 吴庆捷, 等. 耦合辊轮转速对超薄壁环件滚压成形壁厚影响[J]. 汽车实用技术, 2024, 49(18): 116-121.
WU X Z, SHI M Z, WU Q J, et al.Influence of Coupling Roller Speed on Wall Thickness of Roll Forming of Ultra-Thin Walled Rings[J]. Automobile Applied Technology, 2024, 49(18): 116-121.
[12] 赵刚要, 张冉阳, 郭正华, 等. 摩擦对高温合金复杂截面薄壁圆环多道次滚压成形不均匀变形作用[J]. 稀有金属材料与工程, 2018, 47(12): 3761-3767.
ZHAO G Y, ZHANG R Y, GUO Z H, et al.Effect of Friction on Nonuniform Deformation Behavior of Thin-Walled Superalloy Ring with Complex Section in Multi-Pass Rolling[J]. Rare Metal Materials and Engineering, 2018, 47(12): 3761-3767.
[13] 李留柱, 李智军, 李宏伟, 等. 高温合金薄壁W截面密封环滚压成形壁厚变化研究[J]. 精密成形工程, 2019, 11(5): 43-49.
LI L Z, LI Z J, LI H W, et al.Wall Thickness Variation of a Superalloy Thin-Walled W-Section Seal Ring during Roll Forming[J]. Journal of Netshape Forming Engineering, 2019, 11(5): 43-49.
[14] 姜旸, 索双富. W形金属密封环工作状态下综合性能优化设计[J]. 润滑与密封, 2019, 44(1): 76-80.
JIANG Y, SUO S F.Comprehensive Performance Optimal Design of Metallic W-Ring under Working Conditions[J]. Lubrication Engineering, 2019, 44(1): 76-80.
[15] 应帅. W形高温合金封严环滚压成形仿真分析[D]. 南昌: 南昌航空大学, 2013.
YING S.Numerical Simulation of Roll Forming Process for W-Shaped Superalloy Sealing Rings[D]. Nanchang: Nanchang Hangkong University, 2013.
[16] 郭凯云. 高温合金复杂截面圆环多道次滚压不均匀变形行为研究[D]. 南昌: 南昌航空大学, 2015.
GUO K Y.Non-uniform Deformation Behavior in Multi-pass Roll Forming of Superalloy Complex Cross-section Rings[D]. Nanchang: Nanchang Hangkong University, 2015.
[17] 简康. 高温合金复杂截面圆环多道次滚压圆度的控制[D]. 南昌: 南昌航空大学, 2017.
JIAN K.Precision Control of Roundness in Multi-pass Roll Forming of Superalloy Complex Cross-section Rings[D]. Nanchang: Nanchang Hangkong University, 2017.
[18] 胡伟. 高温合金W形密封环滚压成形起皱行为研究[D]. 南昌: 南昌航空大学, 2023.
HU W.Study on Wrinkling Behavior of W-shaped Sealing Ring of Superalloy in Rolling Forming[D]. Nanchang: Nanchang Hangkong University, 2023.
[19] 李明, 庞胜欣. 薄壁加强环滚压成形技术研究[C]//第六届中国航空学会青年科技论坛论文集. 沈阳, 2014: 711-714.
LI M, PANG S X.Research on Rolling Forming Technology of Thin-Walled Reinforced Rings[C]//Collected Papers of Youth Science and Technology Forum of the 6th Chinese Society of Aeronautics and Astronautics. Shenyang, 2014: 711-714.
[20] 梁鑫光, 王洪雨, 许胜, 等. 环状零件滚压加工成形仿真技术研究[J]. 机械制造, 2017, 55(2): 52-55.
LIANG X G, WANG H Y, XU S, et al.Research on Simulation Technology for Forming of Ring-Type Parts by Surface Rolling[J]. Machinery, 2017, 55(2): 52-55.
[21] 郭正华, 康春爽, 赵刚要, 等. 高温合金复杂截面薄壁圆环多道次滚压成形截面变形特征[J]. 失效分析与预防, 2018, 13(2): 67-72.
GUO Z H, KANG C S, ZHAO G Y, et al.Cross Section Deformation Analysis on Multi-Pass Roll Forming of Superalloy Thin-Walled Rings with Complex Cross Section[J]. Failure Analysis and Prevention, 2018, 13(2): 67-72.
[22] 丁军, 张正军, 索双富, 等. 基于ABAQUS的W形金属密封环密封性能研究[J]. 华北科技学院学报, 2023, 20(1): 93-98.
DING J, ZHANG Z J, SUO S F, et al.Research on Sealing Performance of W-Shaped Metal Sealing Ring Based on ABAQUS[J]. Journal of North China Institute of Science and Technology, 2023, 20(1): 93-98.
[23] 郭正华, 应帅, 赵刚要, 等. 高温合金U形环滚压成形有限元建模关键技术研究[J]. 装备制造技术, 2013(6): 1-2.
GUO Z H, YING S, ZHAO G Y, et al.Study on the Key Technology of Rolling Finite Element Modeling Forming Super Alloy U Ring[J]. Equipment Manufacturing Technology, 2013(6): 1-2.
[24] CHEN S W, GAO P F, ZHAN M, et al.Determination of Formability Considering Wrinkling Defect in First-Pass Conventional Spinning with Linear Roller Path[J]. Journal of Materials Processing Technology, 2019, 265: 44-55.
[25] 李恒, 杨合, 詹梅, 等. 薄壁件塑性成形失稳起皱的国内外研究进展[J]. 机械科学与技术, 2004, 23(7): 837-842.
LI H, YANG H, ZHAN M, et al.A Review of the Research on Wrinkling in Thin-Walled Parts Plastic Forming Processes[J]. Mechanical Science and Technology, 2004, 23(7): 837-842.
[26] SHAO G D, LI H W, ZHANG X, et al.External-Internal Composite Spinning Technology for Forming Thin-Walled Ω-Sectioned Ring of Superalloy[J]. Journal of Materials Processing Technology, 2021, 291: 117004.

Funding

Shaanxi Provincial Natural Science Basic Research Program (2025JC-YBMS-473); The Project of Shaanxi Key Laboratory of High-performance Precision Forming Technology and Equipment (SKL-HPFTE) (2020-KF-02); The National Natural Science Foundation of China (51875456)