Ultrasonic-Assisted Spinning V-Groove Moulding Mechanism and Accuracy Research

Spinning forming, a new method for processing multi-ribbed pulleys, is increasingly replacing traditional casting and cutting techniques. However, reducing the substantial forming load remains a challenging task. This paper explores the introduction of ultrasonic assistance into the spinning process to examine the V-groove formation in multi-ribbed pulleys and combines experimental spinning trials with finite element analysis (FEA) to investigate the process. It assesses how ultrasonic aid affects spinning quality under various static loads by analysing V-groove depth, inclination angle, microhardness, structure, and surface roughness. The results indicate that ultrasonic assistance significantly increases the depth of the V-groove in spinning formation. Initially, the V-groove depth is 197.64 μm, which improves to 410.35 μm with ultrasonic aid, corresponding to a reduction in static load by 185 N. The V-groove angle rises with static load, but with ultrasonic assistance, the angle stabilises, enhancing forming accuracy. At a static load of 700 N, the V-groove angle decreases from 74.32° to 62.96°.