Finite-element modelling of a novel flanging process on a cylinder with a large diameter–thickness ratio

Abstract

To solve existing problems of current processing methods for flanged cylinders with a large diameter–thickness ratio, a double-roller clamping spinning (DRCS) process is proposed as a novel flanging process on a cylinder. Finite-element (FE) numerical simulation is used to research the DRCS process. First, on the basis of non-linear FE analysis software Abaqus/Explicit, an FE model for the DRCS process is established. Second, some key problems in FE modelling of DRCS are solved, for example, the definition of contact, the treatment of meshing, the load curves applied on the rollers, the optimal clamping position, and the bending point on the defined initial workpiece. Then, the reliability of the FE model is verified using the energy-conservation principle and experimental results. Finally, the DRCS process of the flange is simulated using the verified FE model, and the equivalent stress field, equivalent strain field, and wall-thickness distribution on the flange during the whole forming process are obtained. The FE model established in this study can be used to explore and develop the DRCS process.