Macroscopic and microscopic deformation mechanism of cup-shaped part made of difficult-to-deform metal during the current-assisted flow spinning process

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology Pub Date : 2025-04-10 DOI:10.1016/j.jmatprotec.2025.118859

Can Chen , Gangfeng Xiao , Qinxiang Xia , Junhao Zhang , Sizhu Cheng

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引用次数: 0

Abstract

Cup-shaped parts with different thin-walled thickness structures are an essential transmission component for the harmonic reducer in aerospace and intelligent robotics engineering. However, those cup-shaped parts are usually prepared from a difficult-to-deform metal with high deformation resistance and poor plasticity at room temperature. This paper explores a current-assisted flow spinning (CAFS) method to reduce deformation resistance, improve plasticity, and promote grain refinement through electroplasticity. To reveal the mechanism of pulse current on macroscopic and microscopic deformation mechanism, a finite element model coupled with the electroplasticity effect is constructed; an experimental platform for the current-assisted flow spinning is set up, and a series of process experiments are carried out. The results show that the current density of the cup-shaped blank is concentrated near the contact area of the roller, so the softening region, due to the electroplasticity effect, highly overlaps with the deformation region of the cup-shaped blank. Thus, as the current intensity increases, the stress and the dangerous area of the cup-shaped part decreases, improving the forming quality of the spun workpiece. In addition, the gradual decrease of the current density along the axial direction from the mouth to the bottom makes the grain refinement accelerated by the electroplasticity effect at the mouth higher than that at the middle, which partially eliminates the uneven microstructure along the axial direction caused by the uneven deformation. The tensile strength and hardness of the spun workpiece under pulse current conditions increase by 8.49 % and 7.42 %, respectively. These findings provide an important theoretical basis for the current-assisted forming process to prepare high-performance and high-precision complex components made of difficult-to-deform metal.

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难变形金属杯形零件在电流辅助流旋过程中的宏观和微观变形机理

不同薄壁厚度结构的杯形零件是航空航天和智能机器人工程中谐波减速器必不可少的传动部件。然而，这些杯形零件通常由难以变形的金属制成，其变形抗力高，室温塑性差。本文探讨了一种电流辅助流动纺丝（CAFS）方法，通过电塑性降低变形阻力，提高塑性，促进晶粒细化。为了揭示脉冲电流对材料宏观和微观变形的作用机理，建立了考虑电塑性效应的有限元模型；建立了电流辅助流纺丝实验平台，并进行了一系列工艺实验。结果表明：杯形坯料的电流密度集中在滚轮接触区附近，因此由于电塑性效应，软化区与杯形坯料的变形区高度重叠；因此，随着电流强度的增大，杯形零件的应力和危险区域减小，提高了旋压工件的成形质量。此外，由于电流密度沿轴向由口向底逐渐减小，使得口处电塑性效应加速晶粒细化的速度高于中间，从而部分消除了变形不均匀导致的沿轴向不均匀的微观组织。在脉冲电流条件下，纺丝工件的抗拉强度和硬度分别提高了8.49 %和7.42 %。这些研究结果为用电流辅助成形工艺制备高性能、高精度难变形金属复杂部件提供了重要的理论依据。

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来源期刊

Journal of Materials Processing Technology 工程技术-材料科学：综合

CiteScore

12.60

自引率

4.80%

发文量

403

审稿时长

29 days

期刊介绍： The Journal of Materials Processing Technology covers the processing techniques used in manufacturing components from metals and other materials. The journal aims to publish full research papers of original, significant and rigorous work and so to contribute to increased production efficiency and improved component performance. Areas of interest to the journal include: • Casting, forming and machining • Additive processing and joining technologies • The evolution of material properties under the specific conditions met in manufacturing processes • Surface engineering when it relates specifically to a manufacturing process • Design and behavior of equipment and tools.