Numerical Simulation of Stagger Spinning for D406A High-Strength Steel

Abstract

Metal spinning process is widely used because of its low power requirement to producing complex symmetry components. In this paper, a modified 3D finite element(3D-FE) model is developed under the FE software environment based on characteristics of stagger spinning process. Analysis of the multi-pass spinning deformation mechanism and the effects of spinning parameters on spinning deformation is carried out. The results show that, large internal diameter of tube blank and low dimensional accuracy are caused by too little feed rate of spinning roller, especially for thin-walled tube. But if the feed rate is larger than 60mm/min, large spinning forces and instability appear. Strain rate and forming instability increase with the increase of rotational speed of mandrels, on the other hand, more obvious friction leads to bigger strain of surface of tube blank. With the radius of corner of spinning roller getting 13mm, the extensive overlaps lead to the improvement of spinning efficiency, while low forming quality accompanied by the large spinning forces occurs. Cutting phenomena leads to worse surface quality even tends to crack with the radius of corner of spinning roller being smaller than 8mm. An ideal combination of process parameters is obtained: the roller feed rate is 50mm/min, the rotational speed of mandrel is 40rad/min, the radius of corner of spinning roller is 10mm.