Abstract Flange wrinkling is one of the common defects that occur in conventional spinning process, severely restricting the improvement of forming quality and formability. How to universally determine the formability dependent on flange wrinkling is a critical issue in conventional spinning process. For this end, such a determining method for the formability in the process is proposed to rationally design the forming parameters to prevent flange wrinkling. The method is as follows: firstly, the maximum circumferential stress during the process is calculated at the outer edge of the flange, where the circumferential stress is considered as the combining result of the shrinkage of flange diameter and the bending of flange; then, the formability is determined by comparing the maximum circumferential stress to critical circumferential stress for wrinkling defect. Based on the method, a formability analytical model considering wrinkling defect in the first-pass conventional spinning process with a linear roller path is established. The formability model is validated by experiments and FE simulations at different spinning conditions. Sequentially, the influences of forming parameters and their interaction on the formability considering wrinkling defect are systematically analyzed. Furthermore, the forming diagrams considering wrinkling defect for the first-pass conventional spinning are established. It is found that the feed ratio has the most significant effect on the formability, followed by the blank thickness, the hardening exponent, the feed ratio-hardening exponent interaction and the feed ratio-sheet blank thickness interaction. The smaller feed ratio and hardening exponent, thicker sheet blank and greater relative sheet blank radius are helpful to increase the formability. The research results could provide a theoretical basis and guidance for the selection of forming parameters in the actual production of the first-pass conventional spinning.

中文翻译：

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直线辊道常规纺丝中考虑起皱缺陷的成形性测定

摘要 法兰起皱是常规旋压工艺中常见的缺陷之一，严重制约了成形质量和成形性的提高。如何普遍确定取决于法兰起皱的成形性是传统纺丝工艺中的关键问题。为此，提出了这样一种工艺中成形性的确定方法，以合理设计成形参数，防止法兰起皱。其方法是：首先计算法兰外缘处的最大周向应力，其中周向应力被认为是法兰直径收缩和法兰弯曲的综合结果；然后，可成形性是通过比较最大周向应力与起皱缺陷的临界周向应力来确定的。基于该方法，建立了考虑直线辊道常规旋压工艺首道起皱缺陷的成形性分析模型。成形性模型通过不同纺丝条件下的实验和有限元模拟得到验证。随后，系统分析了成形参数及其相互作用对考虑起皱缺陷的成形性的影响。此外，还建立了首道常规纺丝考虑起皱缺陷的成形图。结果表明，进给比对成形性的影响最显着，其次是坯料厚度、硬化指数、进给比-硬化指数相互作用和进给比-板坯厚度相互作用。较小的进给比和硬化指数、较厚的板坯和较大的板坯相对半径有助于提高成形性。研究结果可为首道常规纺丝实际生产中成形参数的选择提供理论依据和指导。