Increasing structure stiffness of corrugated aluminum spool

The paper presents the results of a computational and experimental study of aluminum spools with different profile configurations. Mathematical modeling of the product was made using ANSYS 18.2 software package. Models were verified based on actual test results on FP-100/1-10tn testing machine in JSC “Arconic SMZ” Central Factory Lab as per valid normative documents. The study was made on a trial lot of spools with a specially developed type of profile. Comparative analysis was carried out against purchased spools with a profile previously developed by the spool supplier. The spools under study were made of alloy 3104 H19, 0.26 mm strip thickness. The study resulted in work out of empirical formulas helping to determine collapse load and calculate the amount of metal for evaluation of stiffness-to-weight ratio. The proposed formulas were added with dimensionless coefficients to account for the profile configuration (shape factor) and the relative height of the profile wall. The coefficients were presented in the form of nomograms for easy graphical assessment of the profile performance. The critical height of the profile was determined, at which specific stiffness of the structure is the highest. It was demonstrated that a profile with an inclined vertical wall and a profile with an omega-shaped inner generatrix have lower stiffness than a profile with vertical U-shaped corrugations. The optimal range of the corrugation wall tilt angle was determined to ensure the required level of the structure stiffness, on the one hand, and minimize metal consumption, on the other hand. Comparison of the results of model calculations, the results of computation by the proposed empirical dependencies and actual experimental data showed their high repeatability, which leads to the conclusion that the proposed formulas are applicable for engineering calculations. The developed profile of a special type makes it possible to reduce the spool metal consumption by 13% while maintaining the required strength performance and the level of stiffness.