Enhanced finite element models of metal spinning

Abstract Spinning is frequently used for manufacturing axi-symmetric shapes where press tooling might not be justified on grounds of size and production volumes. Spinning also has the possibility of producing parts that cannot be deep drawn. In this paper, conventional spinning is studied that is a rotational forming process that does not set out to change the sheet thickness. Both the blank and the finished product have roughly the same thickness. Previous authors have proposed various analyses of the spinning process. This paper reports the finite element modelling of metal spinning. Domain decomposition is a commercially available technique, which enables the partition of a finite element problem into sub-problems that can be solved by using parallel processing techniques in a greatly reduced time. The software used is MARC as provided by MSC Software. The hardware platforms used were Dell/Intel single and dual processor machines. Earlier papers reported the difficulties that a finite element modelling of spinning presented. An outline is given of how these problems are tackled. Outstanding problems are reviewed with some potential solutions discussed. The results from the finite element models are compared with experimental results obtained using a numerically controlled spinning process. The NC spinning was done using a light gauge sheet aluminium (Al 99.0-Werkstoff 30205, material condition HH, 0.2% yield 110 MPa).