A theoretical calculation method for asymmetric active counter-roller spinning force by combining strain electrical measurement and simulation

Aiming at the lack of theoretical calculation formulas for inner and outer spinning force in the asymmetric counter-roller spinning process, and the difficulty of direct measurement or conversion of indirect measurement of spinning force under the active rotation condition of rollers, as well as the time-consuming simulation analysis, a theoretical calculation method for asymmetric active counter-roller spinning (AACRS) force by combining strain electrical measurement and simulation is proposed. The initial theoretical calculation model of the inner and outer spinning force for the AACRS process is established based on the energy method. Then, the method of combining the indirect electrical measurement with dynamic simulation analysis (IEM&DS method) is proposed, and the equivalent section coefficient S_WE is used as the pivot to obtain the actual spinning force value equivalently. On this basis, the dynamic and static strain analysis test platform is built, and the modified theoretical calculation formula of spinning force under the counter-roller spinning process is obtained based on the dynamic strain test results. The results show that the theoretical calculation method can directly calculate the inner and outer spinning force values more accurately. The relative error between the corrected outer spinning force and the equivalent measured value is only 6.38 %, improving the accuracy by 49.65 % and 3.46 % compared with the uncorrected theoretical calculation and simulation values, respectively. This method effectively enhances the accuracy of spinning force acquisition while reducing the simulation time and experimental costs.