Effect of Intermediate Path on Post-Wrinkle Initiation of the Multi-Pass Metal Spinning Process: Analysis in the Rotating Reference Frame

Abstract

The metal spinning process has been observed in recent major investigations carried out using finite element analysis. One interesting idea has proposed simulating a rotating disc for the simulation of the metal spinning process to reduce computational time. The development of this concept is presented in this paper, including the formal mathematical transformation from the inertial frame to the rotating reference frame, specific FEM configurations with mesh sizes based on a minimized aspect ratio, a mesh convergence study, and the application of a feed rate scale. Furthermore, in the context of the rotating reference frame, the flange geometry after wrinkle initiation is investigated, including the number of peaks and their amplitudes. Using this new approach, it was found that the number of peaks gradually increases from two to eight peaks while their amplitude decreases. In the case of severe wrinkles, the number of peaks stays at four while the amplitude increases dramatically. The intermediate path proves capable of increasing the number of peaks while maintaining a low amplitude. These results will make it possible to design new paths, facilitating the production of defect-free spun parts.