Effect of roller nose radius and release angle on the forming quality of a hot-spinning process using a non-linear finite element shell analysis

Abstract

This research presents a non-linear dynamic finite element (FE) analysis of a tube-spinning process based on the Belytschko—Lin—Tsay shell element with an explicit time integration scheme. A brief description of the FE formulation of a first-order shear deformation shell element as well as plane stress elastoplastic analysis, internal forces calculation, nodal mass calculation, and prediction of stable time step are presented. An explicit FE code is designed and its implementation algorithm is described in detail. The optimum geometry of a roller is attained using the FE simulations of a hot-spinning process with various roller geometries. The dome-forming process of a seamless pressure vessel using modified roller geometry is performed to confirm the successful process predicted by FE simulation. The vessel is cut longitudinally and its profile is measured. A comparison between longitudinal cross-section profiles calculated by the FE analysis and that obtained from the experiment shows a good agreement.