Numerical Simulation Research on a New Spinning Process: Double-Roller Clamping Spinning Process

Thin-wall rotary parts with complex flange geometry have been widely used in many equipments, especially industrial fans and blowers. Conventional stamping and welding methods for those parts have some limitations such as low manufacturability, poor quality and low utilization ratio of material. Thus in this paper, a new spinning process, double-roller clamping spinning process (DCSP), is introduced to form the complex flange shape. During the process, the cylindrical workpiece made from sheet metal is held by the internal expanding clamp device and rotates together with the device, while two spinning rollers deforms and shapes the material of flange region according to the rollers moving paths. In order to deeply investigate deformation mechanisms of DCSP, both 2D and 3D FE simulation models are built and the spinning process for rectangular cross-section shape of flange is simulated by using explicit FE code ABAQUS/explicit. Simulation results show large flange length can induce wrinkles on the inner region of flange. After spinning process simulation, the springback of workpiece is calculated by implicit FE code ABAQUS/standard. The effect of flange length on the thickness reduction of workpiece is obtained by theoretical analysis.