Computer Aided Engineering in the application of rotational forming of axially asymmetric geometries

Abstract

The research presents the results of an innovative metal forming technology: ‘axially asymmetric metal spinning’. Special attention was paid to the influence of two forming conditions: Constant Contact (CC) and Tangential Contact (TC). The influence of Constant Contact and Tangential Contact were examined and compared. The term Constant Contact was used to describe a forming zone fixed at a certain height. This attribute was defined as naturally occurring in axially symmetrical metal spinning. The term Tangential Contact was used as the opposite to Constant Contact. Tangential Contact was used to describe the phenomena of movement of the forming zone. This attribute was defined as naturally occurring in axially asymmetric metal spinning. For the purpose of comparison, an asymmetric mandrel was manufactured, for which two trajectories were engineered. The trajectories were designed with the CC and TC conditions. The Finite Element Method was used to conduct metal forming simulation in simufact.forming software. Experimental trials were performed on the spinning machine MWS—200. Aluminium Alloy 1050 A was used in the FEM and experimental tests. The geometry measurement was performed using an ATOS 3D scanner and GOM Inspect software. The measurement of residual stresses was performed on a Proto iXRD® diffractometer. After determining the specific requirements of the innovative axially asymmetric spinning technology, a special computer program, called RoMeFo, was created. RoMeFo’s purpose was to engineer the trajectory with the TC condition for the mandrel’s full height. Depending on the method used, details with the following heights were manufactured in the experimental trials: CC—22 mm, TC—30 mm and RoMeFo—60 mm.