Abstract
The spinning of an aluminum alloy workpiece with a revolution complex surface is a complicated problem as there are many interrelated factors. In this work, a multi-pass hot spinning process for aluminum alloy 7A04 sheet was adopted, and the process parameters, including forming temperature, feed ratio, roller path, and roller shape, were investigated using finite element simulation. In the simulation, effective plastic strain, metal flowing, maximum equivalent stress, and ovality were analyzed with different forming temperatures, feed ratios, and roller radii. The spinning defects, such as circumferential cracks, longitudinal cracks, and scaly peeling, were also analyzed. Optimal results of the process parameters were found to be a forming temperature of 350 °C and feed ratio of 0.8, 1.2, and 1.0 mm/r for the first, second, and third spin processes, respectively. Furthermore, the optimal roller radii of first, second, and third spin processes were determined to be 30, 45, and 30 mm, respectively, while the respective pass numbers of the three processes were 3, 5, and 4. Finally, the simulation results were further validated through multi-pass hot spinning experiments, which suggest the reasonability of effectiveness of the process parameters.
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