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

Effect of quenching-induced blank distortion on spinning accuracy and quenching-spinning co-optimization for 2219 aluminum alloy thin-walled components | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Effect of quenching-induced blank distortion on spinning accuracy and quenching-spinning co-optimization for 2219 aluminum alloy thin-walled components Zhixin Li, Tianxu Li, Hanpeng Zeng, Zhenyu Liang, Luopeng Xu This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7178022/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract 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. 2219 aluminum alloy Quenching distortion Spinning forming Thin-walled components Process optimization Full Text Cite Share Download PDF Status: Published Journal Publication published 22 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 27 Aug, 2025 Reviewers agreed at journal 23 Jul, 2025 Reviewers invited by journal 23 Jul, 2025 Editor assigned by journal 21 Jul, 2025 First submitted to journal 21 Jul, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7178022","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":489611366,"identity":"a94803e6-27e4-4ff4-9df7-0d148e1d6ff1","order_by":0,"name":"Zhixin Li","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAxElEQVRIiWNgGAWjYBACPmYGNoYEBgkI74OBjRxBLWzIWhhnFKQZE9YCRlDAzPPhcCJhLezszx48bLPIY2A/fHSzjQFzAoixgYDD0g0SzkgUM/Ckpd3OMWDLAzFuENByTCKhQiKxQYLHDKiFp5gByCCghbFNIsEAqsUCyiCghZkNYQuDgQExWtiAWs4AtQC9cLPHIMGYjZBf+PmPP5P82VaX2MB++NiNH3/+y/GDGPi0wIH9AZi9RCkfBaNgFIyCUYAXAAConDz4YORwAQAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0000-0003-0210-4172","institution":"Civil Aviation Flight University of China","correspondingAuthor":true,"prefix":"","firstName":"Zhixin","middleName":"","lastName":"Li","suffix":""},{"id":489611367,"identity":"2e312240-4bc2-4b95-ba0e-b517db702930","order_by":1,"name":"Tianxu Li","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Tianxu","middleName":"","lastName":"Li","suffix":""},{"id":489611368,"identity":"20e82866-9a88-4efe-88f2-b1a4bdb464b9","order_by":2,"name":"Hanpeng Zeng","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Hanpeng","middleName":"","lastName":"Zeng","suffix":""},{"id":489611369,"identity":"abb83139-16ea-47c7-8ce8-e8955430a3f8","order_by":3,"name":"Zhenyu Liang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Zhenyu","middleName":"","lastName":"Liang","suffix":""},{"id":489611370,"identity":"dacca730-9d85-4eb4-89cf-44a8a354778f","order_by":4,"name":"Luopeng Xu","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Luopeng","middleName":"","lastName":"Xu","suffix":""}],"badges":[],"createdAt":"2025-07-21 13:36:16","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7178022/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7178022/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-16547-y","type":"published","date":"2025-09-22T15:57:24+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":92430456,"identity":"7e2c3371-0f7d-48ae-a6c9-3e5aea351e47","added_by":"auto","created_at":"2025-09-29 16:04:57","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1398436,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7178022/v1_covered_d4e2d6b0-3d6e-4b7e-afab-17e5f52121a2.pdf"}],"financialInterests":"","formattedTitle":"Effect of quenching-induced blank distortion on spinning accuracy and quenching-spinning co-optimization for 2219 aluminum alloy thin-walled components","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"2219 aluminum alloy, Quenching distortion, Spinning forming, Thin-walled components, Process optimization","lastPublishedDoi":"10.21203/rs.3.rs-7178022/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7178022/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe 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. 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