Analysis on Effect of Reduction-of-diameter on Flow Characteristics of Thin Shells

XIANG Jincheng; ZHONG Wu; WANG Xiaolin; WANG Jun; CHEN Wei; LI Hongjun

doi:10.3969/j.issn.1674-6457.2026.05.024

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (5) : 259-267. DOI: 10.3969/j.issn.1674-6457.2026.05.024

Advanced Manufacturing Technology and Equipment

Analysis on Effect of Reduction-of-diameter on Flow Characteristics of Thin Shells

XIANG Jincheng¹, ZHONG Wu², WANG Xiaolin², WANG Jun¹, CHEN Wei¹, LI Hongjun^1,*

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Abstract

The work aims to make clear the unclear material flow mechanism in thin shell ring-shaped reduction forming, so as to further clarify the influence of reduction-of-diameter on the material flow patterns to guide the optimization of process parameters and improve the forming quality and stability of thin shells. Taking Q255 thin shell with an outer diameter of 6.8 mm and a wall thickness of 0.2 mm as the research object, and based on the elastoplastic theory, a microelement mechanical model was constructed. Through finite element simulation using Ansys Workbench, combined with node tracking technology, the material flow patterns and stress-strain distribution characteristics were systematically revealed by changing the reduction-of-diameter. The accuracy of the simulation results was verified through forming experiments. The study indicated that material flow exhibited significant bidirectional characteristics during reduction, converging radially toward the mold center while simultaneously diffusing axially toward both ends. Increasing the reduction-of-diameter enhanced the range of material flow and local stiffness, thereby improving wrinkle resistance. However, excessive reduction-of-diameter led to a sharp rise in displacement gradients, disrupting the uniformity of material flow and causing defects such as concentration of local stress and wall thinning. When the reduction-of-diameter was 0.8 mm, the uniformity of material flow was optimal, with displacement gradients and fluctuation indices at relatively low levels, significantly improving forming stability. This study reveals the influencing mechanism of reduction-of-diameter on material flow. When the reduction-of-diameter is 0.8 mm, it can effectively improve the uniformity of material flow and enhance the forming stability. It provides a theoretical and experimental basis for the parameter optimization of the ring-shaped reduction process.

Key words

thin shell / ring-shaped reduction / material flow / finite element analysis

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XIANG Jincheng, ZHONG Wu, WANG Xiaolin, WANG Jun, CHEN Wei, LI Hongjun. Analysis on Effect of Reduction-of-diameter on Flow Characteristics of Thin Shells[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 259-267 https://doi.org/10.3969/j.issn.1674-6457.2026.05.024

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