Experimental study and FEM analysis of forward hot dieless spinning

Mohammad Sedighi,Mehdi Kasaeian-Naeini,Iraj Jalili

doi:10.1051/meca/2018034

Mohammad Sedighi, Mehdi Kasaeian-Naeini + Show 1 more

Open Access

https://doi.org/10.1051/meca/2018034

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Abstract

In this study, the forward hot dieless spinning method is employed in order to fabricate conical tubes using thick aluminum. The process is first examined numerically and then verified by an experimental work. In the numerical study, a 3-D dynamic explicit model is used to solve a common problem in the modeling of the spinning process, the tube is fixed and the roller rotates around the tube. The strain distribution in the tube at various forming passes is studied. The numerical results show that the circumferential strain distribution in different positions of the tube has a negative value whose value increases toward the free end of the tube. Besides, the results indicate that the hardness of the sample increases by about 18% due to the hot dieless spinning process and such a hardness augmentation is obvious along the thickness of the formed tube.

Highlights

The forward hot dieless spinning process is one of the subcategories of mandrel-free spin forming method
The results obtained from Metallography and hardness test of the forming are presented, followed by showing the stress and strain distributions captured from the numerical simulations for the deformed area of the tubes
It occurs mainly due to the frictional contact between the roller and the tube, resulting in an induced strain at the outer surface

Summary

Introduction

The forward hot dieless spinning process is one of the subcategories of mandrel-free spin forming method In this process, a roller is moved on a predefined path, the material is flown in the roller movement direction and the tube is formed after several passes. A roller is moved on a predefined path, the material is flown in the roller movement direction and the tube is formed after several passes This process can have similar advantages with ISMF process, because of the local contact between tool and workpiece which results in lower forming force [1–3]. The benefits of this method including: the variety of product shapes, dieless forming, less necessary equipment, and relevant cost have made it widely popular in various industries needing high precision material processing, such as automotive, aerospace and aviation industries.

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