Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

Abstract

A non-axisymmetric cylinder with an oblique flange has broad application prospects. Spinning is the main production process for this kind of workpiece. Finite element modeling is a necessary method to study some key problems that are difficult to be solved merely through experiments, such as the strain and stress fields in the development of this spinning technology. In this study, the spinning process of a non-axisymmetric oblique flange cylindrical part was established and simulated using ABAQUS/explicit software. The credibility of the simulation result was validated through an experiment. The influence of the axial roller feed along the cylinder wall on the distribution of wall thickness and stress and strain during the forming process was analyzed. The change in stress field and strain field with time was analyzed, and the quantitative relationship between forming conditions and forming results was described. Furthermore, the forming principle of the flange was analyzed. It would be beneficial for flange forming to reduce the increasing distance of the cylinder wall in the 180° direction (parameter c) and the vertical distance from the closest point to the spindle as the roller returns back in the 180° direction (parameter d), to a certain extent. Hence, a workpiece with an ideal appearance was obtained. By comparing the wall thickness distribution, the design and optimization of the roller path were once again verified to be reasonable.