Mechanism and process influence of inner diameter expansion during forward hot spinning of 5A06 aluminum alloy tube

doi:10.21203/rs.3.rs-4842751/v1

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Mechanism and process influence of inner diameter expansion during forward hot spinning of 5A06 aluminum alloy tube

https://doi.org/10.21203/rs.3.rs-4842751/v1

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During hot spinning process of aluminum alloy tube parts, it is easy to have the phenomenon of inner diameter expansion, which makes it difficult to guarantee the dimensional accuracy of tube. For better understanding of the mechanism and find the way to solve this problem, finite element numerical simulation method was applied to systematically study the relation of stress, strain evolution with the inner diameter expansion, and the quantitively influence of spinning process parameters including feed speed, rotation speed, thinning rate, spinning temperature on the inner diameter expansion data. The results show that during the spinning process, there is a line with the same three-dimension principal stress in the radial direction of the tube in the contact area between the roller and the tube, which is the plastic flow boundary of the material. The contact area is divided into two regions by the dividing line. The stress state of these two regions is three-dimensional compressive stress, but the different flow directions of the two regions lead to the inner diameter expansion. The change of spinning process parameters affects the size of inner diameter expansion by affecting the position of plastic flow boundary. Within a reasonable range, the smaller the feed speed, thinning rate and the spinning temperature, the higher the rotation speed, the closer the boundary position to the unformed area of the tube, and the smaller the inner diameter expansion of the tube. The achievement of this study has certain theoretical guiding significance for selecting appropriate process parameters to control the inner diameter expansion amount to improve the dimensional accuracy of spinning forming tube.

Inner diameter expansion

5A06 aluminum alloy

Positive heat strong spinning

Finite element simulation

Dimension accuracy

Spinning forming is a continuous local plastic deformation forming technology ^[1–3], which has the advantages of high forming precision, short production cycle, and can achieve large deformation through small forming force. It can be very effective to prepare thin-walled high-strength aluminum alloy tubes ^[4]. Spinning forming has become an important processing method for small-batch and multi-variety thin-walled shell parts ^[5–7]. 5A06 aluminum alloy is an aluminum-magnesium alloy with high magnesium content and large deformation. It has medium strength and good corrosion resistance, and is a kind of aluminum alloy with good comprehensive performance ^[8–10]. The 5A06 aluminum alloy tube after spinning is widely used in military fields such as aircraft and ships.

During the spinning process, if the process parameters are not properly selected, it will cause uneven deformation of the tube, resulting in tube surface cracking, ovality deviation, bulging, surface rupture and other phenomena. Lu et al. ^[11] analyzed the stress-strain and temperature field changes during the spinning process by finite element simulation, and changed the boundary conditions to reduce the defects such as surface rupture and bell mouth during the spinning process. Zhang et al. ^[12] used finite element numerical simulation to study the influence of friction between the roller and the tube blank on the ovality of the formed part and proposed a suitable friction coefficient to control the ovality. Wei et al. ^[13] used the finite element numerical simulation method to explore the mechanism of port flaring during thin-walled tube thinning spinning, and analyzed the influence of wall thickness on the height of flaring. Zhan et al. ^[14] analyzed the material flow characteristics based on finite element simulation, and studied the control method of tube flaring in the forward spinning process, which improved the forming quality of the tube. Guo et al. ^[15] carried out multi-pass spinning forming of aluminum alloy tube, and obtained the best process parameters to control defects such as axial cracks and longitudinal cracks. Zhang et al. ^[16] analyzed the wrinkling mechanism in the spinning process of the thin-walled vessel head by finite element simulation and experiment.

The inner diameter expansion will seriously affect the dimensional accuracy and shape accuracy of the spinning tube. Through the flow forming experiment of annealed AA6061 tube, Davidson et al. ^[17] found that when the feed rate of the roller is in the range of 50–100 mm / min, the gap between the mandrel and the tube is the smallest, which is beneficial to avoid the expansion. Fazeli et al. ^[18] showed that the thinner the wall thickness of the original tube, the higher the feed speed of the spinning wheel, the lower the rotation speed of the mandrel, the smaller the spinning thinning amount, the shorter the solution treatment time, and the smaller the inner diameter expansion and wall thickness change of the 2024 aluminum alloy tube formed by spinning. Zhong et al. ^[19] processed tube with inner ribs and found that increasing the number of rollers would avoid the diameter growth of tube and reduce the diameter expansion.

At present, most scholars have studied the control of tube cracking, bulging, cracking and other problems in the spinning process and the control of inner diameter expansion, but there is a lack of research on the mechanism of inner diameter expansion in the spinning process. Therefore, it is very important to explore the mechanism of inner diameter expansion and find the influence of process parameters on the expansion. It can not only improve the dimensional accuracy of the formed parts after spinning, but also increase the utilization rate of materials and reduce the production cost. In summary, the selection of process parameters and the defects such as expansion during the spinning process will affect the accuracy of the tube after forming. In this paper, the finite element simulation of spinning forming of 5A06 aluminum alloy tube is carried out. The stress state of tube in spinning process is analyzed, and the mechanism of inner diameter expansion of tube is revealed. Reasonable process parameters are selected to reduce the expansion amount and improve the dimensional accuracy.

2.1 Experimental principle

According to the direction of the tube material flowing with the spinning wheel during the thinning spinning process, the spinning can be divided into forward spinning and reverse spinning. In the forward spinning, the tube rotates with the mandrel around the axis, and the rollers on both sides move along the tube axis, thereby reducing the wall thickness of the tube and increasing the axial length of the tube, as shown in Fig. 1(a). During the spinning process, the inner diameter expansion phenomenon will occur in the tube of the contact area of the spinning wheel (Fig. 1 (b)).

2.2 Experimental material

The tube material used in this study was a 5A06 aluminum alloy and its composition was listed in Table 1.

Table 1 Chemical composition of 5A06 aluminum alloy tube (%, mass fraction)

Mg	Si	Cu	Zn	Mn	Ti	Be	Fe	Al
6.2	0.3	0.09	0.18	0.68	0.06	0.0004	0.32	Residual

The original size of 5A06 aluminum alloy tube is shown in Fig. 2 (a). According to the deformation characteristics of spinning, the mechanical behavior of 5A06 aluminum alloy under thermal deformation was obtained by thermal compression test. The compression specimen was cut from the raw material 5A06 aluminum alloy tube and processed into a φ8 × 12 mm cylinder. The isothermal compression test was carried out by Gleeble-3500 thermal simulation machine. The sample before and after compression is shown in Fig. 2 (b). The deformation temperature is 250°C, 275°C, 300°C, 325°C, 350°C, and the strain rate is 0.1s^− 1, 1s^− 1, 10s^− 1. The obtained true stress-strain curves at different temperatures and strain rates are shown in Fig. 3.

The corresponding elastic-plastic material model is established by using the Johnson-Cook ^[21] constitutive model, which is shown in Eq. 1.

$$\:\sigma\:=\left(157+113.29{\epsilon\:}^{0.048}\right)\left(1+0.0133\text{ln}{\epsilon\:}^{*}\right)\left(1-0.878{T}^{*0.993}\right)$$

Where $\:\sigma\:$ is the equivalent stress; $\:\epsilon\:$ is equivalent strain; $\:{\epsilon\:}^{*}={\epsilon\:}^{\bullet\:}/{\epsilon\:}_{0}^{\bullet\:}$ is a dimensionless strain rate, where $\:{\epsilon\:}^{\bullet\:}$ is the strain rate and $\:{\epsilon\:}_{0}^{\bullet\:}$ is the reference strain rate; $\:{T}^{*}=\left(T-{T}_{0}\right)/\left({T}_{m}-{T}_{0}\right)$ is a dimensionless temperature, where $\:T$ is the test temperature, $\:{T}_{m}$ is the melting point temperature of the material (the melting point temperature is 823.15K), $\:{T}_{0}$ is the reference temperature ^[21].

The maximum error of fitting is less than 5%. The constitutive model established above describe a good description of the hot deformation behavior of 5A06 aluminum alloy.

2.3 Finite element model

In order to reveal the formation mechanism of tube inner diameter expansion, finite element simulation was used to explore the stress-strain state and material flow during tube deformation. In addition, finite element simulation has been proved to be an effective tool for solving metal forming design in terms of metal forming, tooling design and product quality control and assurance. The finite element model of 5A06 aluminum alloy tube spinning is shown in Fig. 4.The initial size of the tube is φ472 mm and the wall thickness is 30 mm. The tube is fixed on the mandrel by tailstock, and tube rotates with the mandrel. The double rollers on both sides feed along the axis of the mandrel. When the roller contacts with the tube, the passive rotation motion is generated due to friction. The simulation process is the same as the actual working condition.

In the simulation, the amplification factor should be used to shorten the simulation time. If the amplification factor is too large, the simulation results will be inaccurate. If the amplification factor is too small, the simulation time will be too long. The finite element model is verified from the aspects of energy balance and geometric similarity. It is generally believed that the simulation process is stable when the ratio of kinetic energy to internal energy of the tube is less than 10%. When the ratio of the pseudo strain energy to the internal energy of the tube is less than 5%, there will be no unreasonable deformation caused by the hourglass problem. As shown in Fig. 5, the ratio of kinetic energy to internal energy is less than the critical value, which verifies the accuracy of the finite element model.

The tube is divided into 8 layers in the radial direction by 8-node reduced integral hexahedron element (C38DRT). After meshing the finite element model, there are 137707 elements and 156206 nodes. In order to reduce distortion of the element, the adaptive meshing technique (ALE) is used to remesh the tube. The penalty contact is used between the tube and the mandrel and the spinning wheel. The Coulomb friction is used to simulate the friction behavior between the components. The friction coefficient is 0.1, and the heat transfer and heat radiation are set between the components to simulate the temperature field change during the spinning process.

2.4 Experimental scheme

The main process parameters studied in this paper are feed rate, thinning rate, spinning temperature and rotation speed. The simulation experiment design scheme is shown in Table 2.

Table 2 Simulation test design

Experimental parameters	Value
Feed speed (mm/s)	1、1.5、2、2.5
Thinning rate (%)	16.7、20、23.3、26.7
Temperature (℃)	250、275、300、350
Rotation speed (rad/s)	5、6、7、8

In order to better describe the relationship between the expanding amount and different process parameters, $\:\varDelta\:R$ is now expressed as the expanding amount. ($\:\varDelta\:R>0$, represents the expansion;$\:\varDelta\:R<0$, indicating shrinkage)

$$\:\varDelta\:R=R-{r}_{0}$$

Where $\:R$ is the inner radius of the tube during the expansion of the spinning process; $\:{r}_{0}$ is the inner radius of the tube before spinning.

3.1 The stress and strain distribution law of the cylinder during hot spinning process

According to the calculated results of the three-dimension spinning force change with time, as shown inFig.6, the spinning process is generally divided into three stages, including the initial stage, the stable stage and the termination stage. The stable stage of deformation is selected to study the stress and strain distribution in the contact area between the roller and the tube.

The distribution of principal stress and strain in the contact area of the roller and the aluminum alloy cylinder in three-dimensional (Axial, Radial and Circumferential) is calculated, and the distribution is shown in Fig. 7 and Fig. 8. In the contact area of the roller, there are significant compressive stresses in all three directions, the radial stress is the largest and the axial stress is the smallest. As shown in Fig. 7 (a), the three-dimensional principal stress coincides at the axial distance of about 77 mm, where the three-dimensional principal stress values are equal. Under the action of external force, the deformation of the object can usually be divided into volume change and shape change, the stress state can be decomposed into two parts, namely the stress sphere tensor and the stress partial tensor. According to the elastic-plastic theory, only the stress sphere tensor exists here, and the material has no shape change but only the volume change. Therefore, this point is the material flow boundary point in the spinning process, that is, the plastic deformation boundary point. As shown in Fig. 8, the radial strain is compressive strain, the axial strain is tensile strain, and the circumferential strain is relatively small. The circumferential strain of the roller in the deformed zone, the contact zone and the undeformed zone is very small. It can be shows that the metal flow of the tube in the deformed zone, the contact zone and the undeformed zone is very small in the circumferential direction. The axial strain is tensile strain in the deformed zone, and the strain in the contact zone is converted into compressive strain due to the accumulation of metal in front. Under the action of the roller, the metal in the deformed zone has a large compressive strain in the radial direction, resulting in compressive deformation. Similarly, tensile deformation occurs in the radial direction of the contact area due to metal accumulation. The three-dimensional strain in the deformed zone is basically stable, the axial tensile strain and the radial compressive strain. There is a slight tensile strain in the circumferential direction.

3.2 Analysis of the formation mechanism of inner diameter expansion

Based on the finite element simulation of the forward hot spinning process, it is known that the formation of the inner diameter expansion phenomenon of the tube during the spinning process is mainly caused by the position of the plastic flow boundary in the contact area of the roller. The material above the dividing line flows forward by the advance of the roller, and material accumulation occurs in front of the roller. As shown in Fig. 9 (a), the dividing line divides the material in the contact area of the roller into two regions A and B, and the material in both regions receives three-way compressive stress. It can be seen from Fig. 9 (b) that the material on the inner surface of the tube in area A flows forward and downward along the axial direction, and the inner diameter of the tube in this area is reduced, which is bonded with the mandrel. From Fig. 8 (c) in the previous section, it is known that the radial strain and the axial strain in the contact area are converted to each other, and the circumferential strain is the tensile strain, so the total strain is the tensile strain. The material on the inner surface of the cylindrical part in the B area flows upward along the radial direction, and the material flows along the circumferential direction to cause the bulge between the cylindrical part and the mandrel. By changing the feed rate, rotation speed, thinning rate and spinning temperature, the position of the plastic flow boundary is changed, so that the direction is along the lower diagonal direction of the roller feed direction, resulting in a decrease in the area of the B area and an increase in the area of the A area. The material flows more smoothly along the axial direction, and finally achieves the purpose of reducing the expansion amount.

4.1 The influence of feed speed

The influence of feed speed on hot spinning inner diameter expansion was studied, where the thinning rate was 20%, the rotation speed was 6rad/s, and the spinning temperature was 300°C. The influence of different feed speed on the diameter expansion amount is shown in Fig. 10 (a). With the increase of feed speed, the diameter expansion amount increases obviously, and the lower feed speed has little effect on the diameter expansion amount. According to the analysis in section 3.2, the tensile circumferential strain (value greater than zero) of the material on the inner surface of the cylindrical part in the B area leads to the expansion of the inner diameter. The influence of feed speed on circumferential strain of the material on the inner surface is shown in Fig. 10 (b). It can be seen from the result that it corresponds to the result of the inner diameter expansion amount, the tensile circumferential strain of inner surface leads to inner diameter expansion, and the larger the value is, the larger amount of the inner diameter expansion is, while compressive circumferential strain of inner surface leads to inner diameter contraction.

Reasonable setting of feed speed can improve the die sticking between mandrel and tube and reduce the diameter expansion amount. As shown in Fig. 10 (c) when the feed speed of the roller is low, the direction of the dividing line is in the direction of the forward lower oblique line and the area of the area B is small, the extrusion of the contact area is relatively sufficient, and the material flow per unit time is small. The lower feed rate can avoid the defects such as peeling on the surface of the pipe, so that the surface of the pipe is uniform. As shown in Fig. 10 (d) when the feed speed of the roller is large, the direction of the dividing line starts from the surface layer to the bottom layer and the area of the area B is large. The insufficient extrusion of the material on the surface of the tube by the rotary wheel leads to a large amount of material flow per unit time and poor fluency along the axial direction, which will lead to unstable plastic deformation of the tube and poor material flow of the tube.

4.2 The influence of rotation speed

The influence of rotation speed on hot spinning inner diameter expansion was studied, where the feed speed was 2 mm/s, the thinning rate was 20%, and the spinning temperature was 300°C. The influence of different rotation speed on the diameter expansion amount is shown in Fig. 11 (a). With the increase of rotation speed, the diameter expansion amount decreases obviously, and when the rotation speed was larger than 7 rad/s, the diameter was changed from expanding to shrinking. As can also be seen from Fig. 11 (b), the circumferential strain of the material on the inner surface was all compression when rotation speed was larger than 7 rad/s.

Figure 11 (c) (d) is the plastic flow boundary position when the rotation speed is 5rad / s and 8rad / s. As shown in Fig. 11 (c), the lower rotation speed will lead to unstable plastic deformation of the tube, and the material fluidity of the tube is poor. The boundary line starts from the surface layer to the bottom layer and the area B is larger. As shown in Fig. 11 (d), when the rotation speed is high, the material flows smoothly along the axial direction, and the direction of the dividing line is in the direction of the forward lower oblique line and the area of the area B is small.

4.3 The influence of thinning rate

The influence of thinning rate on hot spinning inner diameter expansion was studied, where the feed speed was 2 mm/s, the rotation speed was 6 rad/s, and the spinning temperature was 300°C. The influence of different thinning rate on the diameter expansion amount is shown in Fig. 12 (a), and the influence of thinning rate on circumferential strain of the material on the inner surface is shown in Fig. 12 (b). It can be seen from the results that the greater the thinning rate, the higher the diameter expansion amount. The circumferential strain of the material on the inner surface was all compression when thinning rate was less than 20%, and the diameter will change from expanding to shrinking.

As shown in Fig. 12 (c) and Fig. 12 (d), when the thinning rate is small, the material in the tube has less flow under the roller extrusion. The metal resistance near the contact area is small. The material flow in the tube is relatively stable, and the radial reduction changes evenly. With the increase of the thinning rate, the material will produce serious accumulation in front of the roller, which hinders the uniform flow of the material in the axial direction and promotes the flow of the metal in the radial and circumferential directions. When the thinning rate exceeds the appropriate value range (> 20%), the spinning force will increase sharply, and the spinning force is unstable. The direction of the dividing line is opposite to the smaller thinning rate, and the area of the region B increases, resulting in the phenomenon of inner diameter expansion.

4.4 The influence of spinning temperature

The influence of spinning temperature on hot spinning inner diameter expansion was studied, where the feed speed was 2 mm/s, the rotation speed was 6 rad/s, and the thinning rate was 20%. The influence of spinning temperature on the diameter expansion amount is shown in Fig. 13 (a), and the influence of spinning temperature on circumferential strain of the material on the inner surface is shown in Fig. 13 (b). It can be seen from the results, with the increase of spinning temperature, the diameter expansion amount increases, and the diameter expansion amount was the largest when the spinning temperature was 350°C.

As shown in Fig. 13 (c), when the spinning temperature is 275°C, the metal plastic flow performance is good. Good metal fluidity makes the metal in the deformation zone flow rapidly to the front of the roller during the spinning process, and the material fluidity of the surface and bottom layers of the tube is more uniform. As shown in Figu.13 (d), when the temperature rises to 350°C, the plasticity of 5A06 aluminum alloy material increases, whereas the stiffness of the material decreases, resulting in uneven material in the axial flow process of the tube, resulting in local accumulation of materials in the front of the roller. This accumulation hinders the normal flow of the material along the axial direction, and some metal flow directions are deflected from the axial direction to the radial direction, forming a diameter expansion phenomenon.

In this paper, the mechanism of inner diameter expansion of tube in hot spinning process is explored by finite element simulation, and the influence of process parameters on the expansion amount is explored with accuracy as the evaluation index. The main overview is as follows:

The phenomenon of inner diameter expansion of tube always exists in the whole spinning process. By analyzing the stress and strain variation law of the roller contact area in the spinning process, it shows that in the roller contact area, there is a three-dimension stress coincidence point along the radial direction of the tube, which is the plastic flow boundary.

The mechanism of inner diameter expansion of tube in spinning process is analyzed, and the method of reducing the expansion amount is found out. In the contact area, the material on the left side of the boundary flows to the inner surface of the tube, while the material on the right side of the boundary flows to the outer surface of the tube. The circumferential strain of the inner surface of the tube is greater than zero in the right area of the dividing line, and less than zero in other areas, indicating that the expansion is generated in the right area of the dividing line, and the other areas are reduced.

Through the finite element simulation analysis, it can be seen that the process parameters (feed speed, rotation speed, thinning rate, spinning temperature) have a great influence on the expansion amount. With different process parameters, the smaller the expansion amount, the direction of the plastic flow boundary line from the outer surface of the tube to the inner surface along the downward oblique line direction of the roller feed direction and the area of the area B on the right side of the boundary line decreases. Therefore, the tube inner diameter expansion can be controlled by changing the process parameters.

Funding

The authors declare that no funds, grants, or other support were received during the preparation of this manuscript.

Author Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by Zhijian Wang, Henan Yang, Hongwu Song, Xiaofeng Shang, Wenlong Xie, Wentao Zhang and Lijuan Zhang. The first draft of the manuscript was written by Henan Yang and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Competing Interests

The authors have no relevant financial or non-financial interests to disclose.

Competing Interests

The authors have no relevant financial or non-financial interests to disclose.

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Editorial decision: Major Revisions Needed
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Mechanism and process influence of inner diameter expansion during forward hot spinning of 5A06 aluminum alloy tube

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Abstract

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1 Introduction

2 Experimental materials and methods

3 Formation mechanism of hot spinning inner diameter expansion

4 The influence of spinning parameters on hot spinning inner diameter expansion

5 Conclusion

Declarations

References

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