Qin ng Xia

Processing Parameters Optimization for Stagger Spinning of Trapezoidal Inner Gear

Spin-forming of trapezoidal inner gear is a new technology of the near-net forming in gear manufacturing field. Processing parameters, such as the initial thickness of blank and radial reductions of each roller, greatly influence the forming quality of spun part. The forming quality of trapezoidal inner gear involves the filling status of gear tooth and dimensional accuracy of root circle. An approach for processing parameter optimization of the forming quality of the trapezoidal inner gear stagger spinning is proposed. The proposed approach integrates the orthogonal experiment design, gray relational analysis, and analysis of variance (ANOVA). The experiment result indicates that the proposed approach is effective in determining the optimized processing parameters for the stagger spinning of trapezoidal inner gear.

Study on Spinning of Pentagonal Cross-Section Hollow-Part Based on Orthogonal Experiment Design

The investigation of the effect of processing parameters on forming quality has been one of the highlight researches in spinning. The thickness distribution is an important criterion to evaluate the forming quality. Spinning force affects the processing and equipment design greatly. Combining with the FEA simulation and orthogonal test method, taking the maximum reduction ratio in thickness of workpiece and the maximum spinning force as the evaluation criterion, the esequence of the main forming parameters, such as the feed rate and roundness radius of roller, and the relative height of workpiece were analyzed based on an orthogonal scheme of three-factor and three-level. Both FEA simulation and experiment results show that, during the pentagonal section hollow-part spinning, the influence sequence on the maximum reduction ratio in thickness is relative height of workpiece, feed rate and roundness radius of roller; the influence sequence on the maximum spinning force is relative height of workpiece, roundness radius of roller and feed rate.

Analysis on Forming Characteristics of Cup-Shaped Thin-Walled Inner Gear Spinning

Spin-forming is a new near net-shape forming process for cup-shaped thin-walled inner gear (CTIG). The CTIG spinning was investigated by numerical simulation and processing experiments. The results show that the compressive deformation along tangential direction on the internal surface of part leads to a reduction in root circle of spun part; and the local loading and friction work result in the nonuniform radial deformation on the external surface of spun part. For spin-forming of CTIG with a small number of teeth, the diameter reduction is feasible for improving the forming quality of tooth groove, while the nonuniform radial deformation would cause concaves on external surface of part. For spin-forming of CTIG with a large number of teeth, the diameter reduction is not conducive to removing the part from the mandrel.

Finite Element Analysis of Residual Stress/Strain for Composite Material Part with Zinced Sheet/TPO during Forming Process

Based on the indirect thermal-stress coupled strategy that the first analysis was temperature field and the second analysis was stress field, the process induced residual stress/strain of composite parts with zinced sheet and TPO was numerical simulated by ANSYS software. Moreover, history of residual stress/strain at along fiber orientation and vertical fiber orientation composite material were analyzed. Compared to the forming of composite material part in test, the validity of the results calculated by model was proved.

Structure Design and Simulation of Lithium-Ion Battery Casing Machine

Considering the self-structure of lithium-ion battery and features of lithium-ion battery casing machine, the detailed design and analysis were carried on the components of lithium-ion battery casing machine. The motion simulation and finite element analysis were conducted by ADAMS and MARC software. The results show that the structure is practicable and the design is reasonable.

Forecast on Upsetting Crack Based on Numerical Simulation

To improve the forging quality and avoid longitudinal cracks on forging surface, critical hole expansion ratio of ductile failure of metallic materials micromechanics was adopted as the criterion to judge whether crack occurs during upsetting, and the upsetting FEA model of 5CrNiMo hot die steel was established based on FEM software DEFORM-3D. The dangerous points on forging surface which crack may occur easily were analyzed based on the calculating results of the metal hole expansion ratio, and the influence of forgings shape on upsetting cracks were researched. The results show that when the relative reduction of the center point on the forgings surface exceeds 65%, the first crack occurs during upsetting; the shape coefficient can be used as the conditions and basis for cracks forecast by establishing the comparison expression between shape coefficient and hole expansion ratio during upsetting.

Finite Element Simulation and Experimental Research in Insulation Spacer Blanking

Blanking finite element analysis model of non-metallic material PET insulation spacer was established, and the influence of process parameters on blanking quality of insulation spacer was analyzed. The results show that the qualified cross-section quality, the high dimensional accuracy and the little bending distortion of blanking workpiece can be obtained by the reasonable blanking clearance and the higher blanking speed. The corresponding experiment was carried out, the results show that the process parameters of insulation spacer blanking obtained by numerical simulation are feasible, and the qualified insulation spacer was produced by the simulation results.

Design of Control System for Lithium-Ion Battery Automatic Casing Machine Based on PLC

The structure and the control requirements of lithium-ion battery casing machine and the processes of casing were analyzed, and the automatic control system of cylindrical lithium-ion battery 18650 casing machine was designed based on Mitsubishi PLC. The control program of lithium-ion battery casing machine was designed using GX Developer programming software, and the man-machine interface program of the equipment was designed using GT Designer software, in order to operate and monitor the equipment.

Influence of Roller on Tooth Height of Internal Spline Formed by Spin-Forming

Spin-forming of part with internal tooth is a new technology of the near-net forming in gear manufacturing field. And the main purpose of the parts spin-forming is to shape teeth on the internal surface of blank. In order to improve the forming quality of internal tooth, the effect of roller on tooth height of spline was investigated by processing experiments and finite element simulation. The result indicates that, for full-radius roller, a large nose radius has also witnessed a discernible growth in spinning force and tooth height; considering the uniformity of tooth height distribution of spun part and decrease in forming force, the bio-conical roller is more suitable for this forming process

Influence of Slide Stroke Curves on Forming Quality of Box Shaped Part during Deep Drawing

To explore the influence of slide stroke curves on deep drawing and solve the problems of cracking and wrinkling during drawing, the deep drawing processes of box shaped part with the conventional mechanical press and servo press were simulated, respectively. The variation rules of cracking and wrinkling for box shaped part by different slide stroke curves were obtained. It shows that the qualified parts can be obtained more easily when drawing with servo presses by decreasing the rotational speed of servo motor at the forming stage due to its variability; drawing cycle can be shorten effectively by adjusting the variable displacement-velocity curves of servo press.