Towards a blank design method for manufacturing big-tapered profiled ring disk by spinning-rolling process

The big-tapered profiled ring disk is a key component of engines for rockets and missiles. A new forming technology, as called spinning-rolling process, has been proposed previously for the high performance, high efficiency and low-cost manufacturing of the component. Blank design is the key part of plastic forming process design. For spinning-rolling process, the shape and size of the blank play a crucial role in process stability, deformation behavior and dimensional accuracy. So this work proposes a blank design method to determine the geometry structure and sizes of the blank. The mathematical model for calculating the blank size has been deduced based on volume conservation and neutral layer length invariance principle. The FE simulation and corresponding trial production of an actual big-tapered profiled ring disk show that the proposed blank design method is applicative. In order to obtain a preferred blank, the influence rules of blank size determined by different deformation degrees (rolling ratio k) on the spinning-rolling process are revealed by comprehensive FE simulations. Overall considering the process stability, circularity of the deformed ring disk and forming forces, a reasonable range of deformation degree (rolling ratio k) is recommended for the blank design of the new spinning-rolling process.