Numerical simulation and experimental investigation: Metal spinning process of stepped thin-walled cylindrical workpiece

Year 2022, , 67 - 80, 30.01.2022

Mirsadegh Seyedzavvar , Mirali Seyedzavvar Samad Nadimi Bavil Olıaeı , Hossein Abbasi

https://doi.org/10.31127/tuje.824890

Cited By: 1

Abstract

Many equipment and devices utilized in the aerospace industry are formed as symmetric parts through high plastic deformation of high strength sheet metal alloys with low thickness. Considering the inherent advantages of the spinning process of simple tooling and concentrated deformation loading, this process can be considered as one of the main options in producing these thin-sectioned lightweight parts. In this study, a Finite Element (FE) model has been developed to simulate the formation of a stepped thin-walled cylindrical workpiece of AISI 316 stainless steel alloy by spinning process. The FE simulation results were employed to investigate the effects of process parameters, including feed rate of the roller and rotational velocity of the mandrel on the distribution of stress and strain in the sheet metal, wrinkling failure, and thinning of the sheet metal during deformation. Experiments were carried out using selective input parameters based on the results of FE simulations. The comparison between FE simulations and experiments revealed that the developed model could predict the thinning of the sheet metals with over 93 % accuracy. Additionally, a good agreement between the experimentally deformed sheet configurations with those resulting from finite element simulations has been observed.   

Keywords

sheet metal, spinning process, feed rate, mandrel rotational speed, stress and strain, wrinkling

References

• Ahmed K I, Gadala M S, El-Sebaie M G (2015). Deep spinning of sheet metals. International Journal of Machine Tools and Manufacture, 97, 72-85.
• AMS 5528. Stainless Steel Sheet, United Performance Metals, https://www.upmet.com/products/stainless-steel/17-7-ph
• Becker C, Erman Tekkaya A (2015) Wall thickness distribution during a combined tube spinning and bending process. Key Engineering Materials, 651-653:1614−1619.
• Bi D, Yang G, Chu L, Zhang J, Wang Z (2012). Numerical simulation on spinning forming process of automotive wheel rim. Materials Science Forum, 704-705:1458–1464.
• Callister W D, Rethwisch D G (2010). Materials science and engineering: An introduction, 8th edition. John Wiley & Sons, Inc.
• Cheong W C, Kam H K, Wang C C, Lim Y P (2013). Study of cold rotary forming by using rigid-plastic finite element method. Advanced Materials Research, 626, 662–666.
• Davidson M J, Balasubramanian K, Tagore G R N (2008). An experimental study on the quality of flow-formed AA6061 tubes. Journal of materials processing technology, 203(1-3), 321-325.
• Dynamic analysis procedures (DAP): overview, Abaqus analysis user’s guide, Dassault Systemes, https://bit.ly/2IMZ80R
• Feifei S, He Y, Heng L, Mei Z, Guangjun L (2013). Springback prediction of thick-walled high-strength titanium tube bending. Chinese Journal of Aeronautics, 26: 1336–1345.
• Huang C C, Hung J C, Hung C, Lin C R (2011). Finite element analysis on neck-spinning process of tube at elevated temperature. The International Journal of Advanced Manufacturing Technology 56:1039–1048.
• Jahazi M, EbrahimiG (2000). The influence of flow-forming parameters and microstructure on the quality of a D6ac steel. Journal of materials processing technology, 103, 362–366.
• Jia Z, Han Z R, Xu Q, Peng W F, Kong Q M (2015). Effects of processing parameters on the surface quality of square section die-less spinning. The International Journal of Advanced Manufacturing Technology, 80(9), 1689-1700.
• Kalpakjian S, Schmid S R (2006). Chp 16: Sheet metal forming process and equipment, Manufacturing engineering and technology. 6th edition, Pearson Publication.
• Kleiner M, Göbel R, Kantz H, Klimmek C H, Homberg W (2002). Combined methods for the prediction of dynamic instabilities in sheet metal spinning. CIRP Annals 51:209–214.
• Li Y, Wang J, Lu G D, Pan G J (2014). A numerical study of the effects of roller paths on dimensional precision in die-less spinning of sheet metal. J Zhej Uni-SCI A (App Phy Eng) 15(6):432−446.
• Marghmaleki I S, Beni Y T, Noghrehabadi A R, Sadat Kazemi A, Abadyan M (2011). Finite element simulation of thermomechanical spinning process. Proc Eng 10:3769–3774.
• Molladavoudi H R, Djavanroodi F (2011). Experimental study of thickness reduction effects on mechanical properties and spinning accuracy of aluminum 7075-O, during flow forming. The International Journal of Advanced Manufacturing Technology 52:949–957.
• Mori K, Nonaka T (2005). Simplified three-dimensional finite element simulation of shear spinning process based on axisymmetric modeling. Journal of manufacturing processes, 7(1),51–56.
• Moria K, Ishigurob M, Isomura Y (2009). Hot shear spinning of cast aluminum alloy parts. Journal of Materials Processing Technology, 209:3621–3627.
• Murata M, Kuboki T, Murai T (2005). Compression spinning of circular magnesium tube using heated roller tool. Journal of materials processing technology, 162, 540-545.
• Parsa M H, Pazooki A M A, Nili Ahmadabadi M (2009). Flow-forming and flow formability simulation. The International Journal of Advanced Manufacturing Technology, 42(5-6), 463-473.
• Russo I M, Cleaver C J, Allwood J M, Loukaides E J (2020). The influence of part asymmetry on the achievable forming height in multi-pass spinning. Journal of Materials Processing Technology, 275, 116350.
• Sangkharat T, Dechjarern S (2017). Spinning process design using finite element analysis and Taguchi method. Procedia Engineering, 207, 1713–1718.
• Sreenivasan, P R, Rayb S K (2001). Mechanical Testing at High Strain Rates. Enc. Mater.: Sci. Tech. (2nd Ed.) 5269–5271.
• Sugita Y, Arai H (2015). Formability in synchronous multipass spinning using simple pass set. Journal of Materials Processing Technology, 217, 336-344.
• Wang L, Long H, Ashley D, Roberts M, White P (2010). Effects of the roller feed ratio on wrinkling failure in conventional spinning of a cylindrical cup. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 225(11), 1991-2006
• Wang X X, Zhan M, Fu M W, Guo J, Xu R Q, Lei X P (2017). A unique spinning method for grain refinement: repetitive shear spinning. Procedia Engineering, 207,1725–1730.
• Wong C C, Danno A, Tong K K, Yong M S (2008). Cold rotary forming of thin-wall component from flat-disc blank. Journal of materials processing technology, 208:53–62.
• Wong C C, Dean T A, Lin J (2003). A review of spinning, shear forming and flow forming processes. International Journal of Machine Tools and Manufacture, 43(14), 1419-1435.
• Xia Q, Cheng X, Long H, Ruan F (2012). Finite element analysis and experimental investigation on deformation mechanism of non-axisymmetric tube spinning. The International Journal of Advanced Manufacturing Technology, 59(1-4), 263-272.
• Zhan M, Guo J, Fu M W, Li R, Gao P F, Long H, Ma F (2018). Formation mechanism and control of flaring in forward tube spinning. The International Journal of Advanced Manufacturing Technology, 94, 59–72.