Investigation of dimensional accuracy in spinning process using experimental work and FE simulation

Spinning process recently became an advanced plastic working technology and is used for manufacture someaxisymmetric parts. To begin a manufacturing process, first, a metal blank is fixed on the mandrel that clamped on thespindle. Then the blank with the spindle start rotating at a high speed causes the blank to be formed and converted intoan axisymmetric part by using a roller, which gradually pushes the blank against a mandrel. In this paper, to find theeffect of main process parameters such as tool feed rate, mandrel rotational velocity and feed ratio (the ratio of tool feedrate to mandrel rotational velocity) on the dimensional accuracy (due to spring-back) of Al-6061-O conical parts, anexperimental investigation and finite element analysis were performed. Finally, a comparison between the experimentaland numerical results was undergone and found a good agreement between them. It was observed that as the feed rateincreases and rotational velocity decreases, the inside diameter will be increased. There was also no change in thedimensional accuracy when the feed ratio remains constant.

Keywords:

Spinning process , Dimensional accuracy , Spring-back , Numerical simulation , Finite element method