Flow diversion mechanisms and control methodology in asymmetric spinning of special-shaped multi-wedge belt pulley

作者：Xue, Kemin; Zhou, Jinliang; Yan, Siliang; Li, Ping^*

来源：INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, 2022, 119(7-8): 5289-5302.

DOI：10.1007/s00170-020-05496-3

• Special-shaped multi-wedge belt pulley
• Flow diversion
• Spinning flattening
• 3D finite element simulation
• Optimization

A four-procedure spinning forming process for manufacturing special-shaped multi-wedge belt pulley (MWBP) was proposed in this paper, which can be applied on spinning technology to produce special-shaped MWBP with web plate and cylinder. First two procedures for obtaining the preformed blank for toothing were investigated through 3D finite element (FE) simulation and experiment, including the spinning shunting procedure and the spinning flattening procedure. Based on the FE simulation results of the spinning shunting procedure, the change of the effective stress and effective plastic strain, the evolution of metal velocity field, and the plastic flow rules were studied. The asymmetric flow diversion of the blank in different positions was discussed, and volume ratio of the upper part and lower part metal (n) of the special-shaped MWBP affected by different positions. The best distance between the upper end of roller 1 and the blank (M) is 8.38 similar to 8.44 mm verified through the experiment. Moreover, the process optimization by controlling the upper fillet size of roller 1 (r(1)), the feed ratio of the rollers (f), and the friction coefficient (u) was studied by FE simulation. The results show that the n, wall thickness deviation, and ellipticity of the preformed blank for toothing were improved by utilizing the optimized forming parameters and the target parts were formed with high quality through experiments.