Effect of quenching-induced blank distortion on spinning accuracy and quenching-spinning co-optimization for 2219 aluminum alloy thin-walled components

The quenching-spinning is an emerging process for achieving high-performance manufacturing of 2219 aluminum alloy thin-walled components. However, quenching-induced distortion in 2219 aluminum alloy blanks critically influences the formation laws during spinning process, necessitating process optimization for high-accuracy forming. Through integrated finite element (FE) simulation and experimental validation, this study investigates the distortion characteristic during immersion quenching and their effects on the geometric accuracy of thin-walled components, followed by spinning process optimization. The quenching process causes significant bending distortions in the circular blanks, and the distortion mode is depended on the immersion rate. A higher immersion rate generates saddle-shaped distortion mode, whereas a lower rate produces shovel-shaped profiles with greater distortion degree. Comparative forming analyses show that saddle-shaped blanks reduce flange fluctuation and improve circumferential stress uniformity, indicating better process stability. As a result, the component-mandrel gap after forming is smaller when using saddle-shaped blanks, and the roundness is noticeably better. Installation orientation optimization demonstrates that mounting the saddle-shaped blank with its concave surface toward the mandrel for spinning process can reduce the component-mandrel gap and increase roundness. Parameter optimization identifies that the maximum negative deviation ratio has the greatest effect on the spinning accuracy, followed by the roller nose radius, roller feed ratio, and roller oblique angle. Experimental results confirm the reliability of the optimized process for achieving components with high accuracy.