Near-net forming of aerospace ring components: A simulation and experimental study

The aluminum alloy Y-ring adapter, a mission-critical component in rocket propellant tanks, performs dual essential functions: enabling triaxial weld integration and sustaining extreme takeoff payloads under cryogenic conditions. Conventional fabrication of Y-rings via rectangular ring rolling exhibits significant inefficiencies, with material utilization rates below 10% and consequent downstream processing challenges. This study introduces a transformative near-net shaping methodology utilizing closed-die ring rolling to manufacture precision Y-ring forgings. Through coupled finite element (FE) simulation and experimental analysis, we systematically characterize metal flow behaviors, enabling geometry optimization of preform blanks to achieve superior die cavity filling. Experimental validation was conducted on a Φ3500 mm ring rolling machine, forming ring forgings with precise cross-sections. Microstructural analysis demonstrates substantial grain refinement across 83% of sectional areas, while multi-axial tensile testing reveals exceptional elongation properties. These breakthroughs establish a transformative framework for high-performance precision manufacturing of aerospace ring components, providing valuable design and processing guidance for industrial Y-ring rolling applications.