Three-directional contact force model for the ball spinning of a thin-walled tube

This paper provides a computational model for calculating three-directional ball spinning force in accordance with the theory of space analytic geometry. The contact boundary equation of the ball and tube is obtained. By projection, the two-dimensional curve in each coordinate plane is acquired. The projected area of the contact zone in the coordinate plane is calculated through the curve integral. It is assumed that the average pressure of the forming region is nearly equal to that when the steel ball is pressed into the tube. Hence, the unit pressure of the deformation zone is obtained. Then, the spinning component force and total spinning force are calculated. Using a Tu1 thin-walled tube of oxygen-free copper as experimental object, a ball spinning experiment is conducted, the axial spinning components force are tested and the ball spinning force calculation model is verified. Based on deformation rate, backward sliding accumulation and extension and frictional heating, the factors influencing calculation error are analysed at the end of this paper.

Influence of Process Parameters on Spinning Force Using Finite Element Analysis and the Taguchi Method

Metal spinning process is widely used for producing complex symmetry components. Main advantage of spinning process is a lower power requirement for large deformation with good surface finish. The aim of this paper is to investigate the influences of spinning process parameters, on spinning force. A three dimensional finite element model of the spinning process of SPCC sheet was successfully developed using elastic-plastic material property. The spinning experiments were carried out on a turning lathe and spinning forces were measure forces using a piezoelectric force transducer. The finite element prediction was compared with the experimental measurements and the results agreed well. Applying the Taguchi method, the effect of four process parameters, i.e. roller diameter, spindle speed, feed rate and feed depth, on spinning force were studied. The Taguchi main effect analysis and ANOVA results show that roller diameter and feed depth are the most important factor influencing the spinning force.

Effect of Wall Thickness of the Billet on 1Cr18Ni9 Stainless Steel Tube Stagger Spinning Process

The stagger spinning process of 1Cr18Ni9 tube was investigated by using finite element method. The metal flow rule around the roller during the tube stagger spinning was analyzed. The influences of wall thickness of the billet on effective stress and spinning force were studied using software Deform. The simulated results indicate that the proper wall thickness of the billet should be 8~15 mm, for the billet with length of 100mm and inner diameter of 200mm.

The FEM Numerical Simulation of Die Spinning with Three-Dimensional

A three-dimensional finite element model for die spinning of a cylindrical workpiece is established and a practical spinning process of 5A06 alloy tube is simulated with the model and Marc software. The rotation of the workpiece driven by the die and the passive rotations of spinning wheels due to the friction between the spinning wheels and the workpiece are considered in this model. The distributions of stress and strain of deformation region are analyzed. The phenomena during tube spinning are simulated, such as build-up, shape distortion, diametric reduction and increment. From the simulated results, it is concluded: Consideration of the quality and efficiency of production, spinning speed should not be too large. In this study, the simulation process should not exceed 0.8mm/s the traction speed. Spinning force is direct proportional to the traction speed and inverse proportion to the tip radius. This model reprents the spinning deformation behaviors completely. Simulation results correspond with the experiments very well.