Formation mechanism of multi-hierarchy ribs in local hot spinning of 2219 aluminum alloy cylinders
摘要
High-strength aluminum alloy cylinders with multi-hierarchy ribs (MHRs) are widely used in aerospace field. However, their integrated forming methods still require further exploration due to the complex inner rib structures. In this study, a splint mandrel was designed and local heating spinning was employed to form the multi-hierarchy ribbed cylindrical parts. To reveal the forming mechanism of MHRs, the influence of key forming parameters on rib height and material flow behaviour was investigated based on finite element simulation and experiments. The results indicate that the height of longitudinal inner ribs (LIRs) is mainly affected by circumferential compressive strain, while the transverse inner ribs (TIRs) mainly rely on radial filling of material. The application of local heating effectively promotes circumferential material flow and significantly improves the filling quality of LIRs. Owing to the small size of rib groove, secondary inner ribs (SIRs) take shape rapidly with higher rib height under low thinning ratios. On the contrary, the wider and thicker main inner ribs (MIRs) achieve greater rib height under larger thinning ratios and feed ratios. The complex strain interaction between the inner and outer surfaces is a vital factor that affects rib height uniformity and surface quality. To improve the inner rib height, larger wall thickness reduction and feed ratio should be used.