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How to control the uniformity of wall thickness in spin forming
Category：answer Publishing time：2025-10-08 03:58:35 Browse： Times
Spin forming is a metal plastic forming process widely used in aerospace, automotive, pressure vessels and other fields, especially suitable for the manufacturing of thin-walled rotatable components. Its core principle is to cause plastic deformation of the metal material under the constraint of the mold or mandrel by rotating the workpiece and applying external force, thereby obtaining the desired shape. In the process of spin forming, the uniformity of wall thickness is one of the important indicators for evaluating product quality, directly affecting the mechanical properties, service life and processing efficiency of the components. Therefore, how to effectively control the uniformity of wall thickness during the spin forming process has become a key issue.
One, Main factors affecting the uniformity of wall thickness
1. Equipment accuracy and stability
The main spindle accuracy, guide rail stability, and pressure fluctuations of the hydraulic system of the hydroforming equipment will directly affect the contact state between the roller and the workpiece, thereby affecting the uniformity of metal flow.
2. Die and mandrel design
The shape design, surface roughness of the die and mandrel, and the fitting clearance with the workpiece will affect the flow direction and speed of materials, thereby affecting the distribution of wall thickness.
3. Hydroforming process parameters
Including feed speed, roller pressure, spindle speed, and other parameters. Unreasonable parameter settings can lead to excessive local stretching or compression, causing uneven wall thickness.
4. Raw material properties
The degree of anisotropy of materials, yield strength, plastic deformation capacity, and other factors will affect their flow behavior during the hydroforming process.
Two, Key technical measures for controlling the uniformity of wall thickness
1. Optimization of hydroforming path and trajectory control
Numerical control hydroforming technology is adopted to guide the metal flow accurately by programming the movement trajectory and feed amount of the roller. Reasonable design of the hydroforming path can effectively avoid local stress concentration and improve the uniformity of wall thickness.
2. Reasonable selection of process parameter combinations
In actual production, the hydroforming parameters should be adjusted through experiments to find the optimal process window. For example, appropriately increasing the spindle speed helps the material to flow uniformly; controlling the feed rate can prevent local over-thinning.
3. Use multi-pass hydroforming process
For complex or high-precision parts, the multi-pass hydroforming method of 'rough hydroforming + fine hydroforming' can be adopted to gradually correct wall thickness deviations in each pass, ultimately achieving a good uniformity effect.
4. Strengthening die design and surface treatment
CAD/CAM technology is used for die simulation design to ensure the rationality of metal flow path. At the same time, the die surface is polished or coated to reduce friction resistance and improve the forming quality.
5. Introduction of online detection and feedback control system
Online wall thickness detection is realized by using technologies such as laser thickness gauges and eddy current testing, and combined with closed-loop control systems to adjust hydroforming parameters in real time, thus dynamically controlling the uniformity of wall thickness.
Three, Conclusion
With the continuous advancement of manufacturing technology, hydroforming has developed from traditional empirical operations to a direction of precision and automation. Controlling the uniformity of wall thickness is not only a key link to improve product quality but also an important guarantee for promoting the development of hydroforming technology towards the high-end manufacturing field. In the future, through means such as intelligent control and digital simulation, hydroforming will further improve production efficiency and material utilization rate on the basis of ensuring the uniformity of wall thickness, providing more high-quality and efficient processing solutions for modern manufacturing industries.
Spin forming is a metal plastic forming process widely used in aerospace, automotive, pressure vessels and other fields, especially suitable for the manufacturing of thin-walled rotatable components. Its core principle is to cause plastic deformation of the metal material under the constraint of the mold or mandrel by rotating the workpiece and applying external force, thereby obtaining the desired shape. In the process of spin forming, the uniformity of wall thickness is one of the important indicators for evaluating product quality, directly affecting the mechanical properties, service life and processing efficiency of the components. Therefore, how to effectively control the uniformity of wall thickness during the spin forming process has become a key issue.
One, Main factors affecting the uniformity of wall thickness
1. Equipment accuracy and stability
The main spindle accuracy, guide rail stability, and pressure fluctuations of the hydraulic system of the hydroforming equipment will directly affect the contact state between the roller and the workpiece, thereby affecting the uniformity of metal flow.
2. Die and mandrel design
The shape design, surface roughness of the die and mandrel, and the fitting clearance with the workpiece will affect the flow direction and speed of materials, thereby affecting the distribution of wall thickness.
3. Hydroforming process parameters
Including feed speed, roller pressure, spindle speed, and other parameters. Unreasonable parameter settings can lead to excessive local stretching or compression, causing uneven wall thickness.
4. Raw material properties
The degree of anisotropy of materials, yield strength, plastic deformation capacity, and other factors will affect their flow behavior during the hydroforming process.
Two, Key technical measures for controlling the uniformity of wall thickness
1. Optimization of hydroforming path and trajectory control
Numerical control hydroforming technology is adopted to guide the metal flow accurately by programming the movement trajectory and feed amount of the roller. Reasonable design of the hydroforming path can effectively avoid local stress concentration and improve the uniformity of wall thickness.
2. Reasonable selection of process parameter combinations
In actual production, the hydroforming parameters should be adjusted through experiments to find the optimal process window. For example, appropriately increasing the spindle speed helps the material to flow uniformly; controlling the feed rate can prevent local over-thinning.
3. Use multi-pass hydroforming process
For complex or high-precision parts, the multi-pass hydroforming method of 'rough hydroforming + fine hydroforming' can be adopted to gradually correct wall thickness deviations in each pass, ultimately achieving a good uniformity effect.
4. Strengthening die design and surface treatment
CAD/CAM technology is used for die simulation design to ensure the rationality of metal flow path. At the same time, the die surface is polished or coated to reduce friction resistance and improve the forming quality.
5. Introduction of online detection and feedback control system
Online wall thickness detection is realized by using technologies such as laser thickness gauges and eddy current testing, and combined with closed-loop control systems to adjust hydroforming parameters in real time, thus dynamically controlling the uniformity of wall thickness.
Three, Conclusion
With the continuous advancement of manufacturing technology, hydroforming has developed from traditional empirical operations to a direction of precision and automation. Controlling the uniformity of wall thickness is not only a key link to improve product quality but also an important guarantee for promoting the development of hydroforming technology towards the high-end manufacturing field. In the future, through means such as intelligent control and digital simulation, hydroforming will further improve production efficiency and material utilization rate on the basis of ensuring the uniformity of wall thickness, providing more high-quality and efficient processing solutions for modern manufacturing industries.
