Investigation of wrinkling failure mechanics in metal spinning by Box-Behnken design of experiments using finite element method

An investigation into material wrinkling failure mechanics of conventional metal spinning and the effects of process parameters and material properties are presented in this paper. By developing finite element (FE) models using the Box-Behnken design of experiments, the effects of six key process and material parameters on the start of material wrinkling have been investigated. These key factors include roller feed per pass, feed rate, blank thickness, tool path profile, material Young’s modulus, yield stress and strain hardening exponent. The results of FE simulation are validated by comparing the modelled roller tool forces and spun part end shape with those measured during a spinning experiment.From FE simulations, large residual stresses in the form of bending moments are found to be present in the flange of the blank, induced by the roller contact. It is found that material wrinkling failure begins when a plastic hinge is formed between the roller and the edge of the blank. It is found that both roller feed per pass and feed rate produce the most significant effect on the initiation of wrinkling failure, as they increase the bending stresses causing a plastic hinge to form more rapidly, thus wrinkling to occur more quickly.

[1]  Trevor A. Dean,et al.  A review of spinning, shear forming and flow forming processes , 2003 .

[2]  L. Wang,et al.  A study of effects of roller path profiles on tool forces and part wall thickness variation in conventional metal spinning , 2011 .

[3]  Shiro Kobayashi.  Instability in Conventional Spinning of Cones , 1963 .

[4]  Richard L. Kegg,et al.  A New Test Method for Determination of Spinnability of Metals , 1961 .

[5]  Hui Long,et al.  Effects of the roller feed ratio on wrinkling failure in conventional spinning of a cylindrical cup , 2011 .

[6]  Masujiro Hayama,et al.  Roller Pass Programming in Conventional Spinning by NC Spinning Machine , 1987 .

[7]  B. W. Senior.  Flange wrinkling in deep-drawing operations , 1956 .

[8]  Alexander Brosius,et al.  Process Characterization of Sheet Metal Spinning by Means of Finite Elements , 2007 .

[9]  H. Kantz,et al.  Combined Methods for the Prediction of Dynamic Instabilities in Sheet Metal Spinning , 2002 .

[10]  Julian M. Allwood,et al.  A review of the mechanics of metal spinning , 2010 .

[11]  Farid R. Biglari,et al.  Study of Strains Distribution in Spinning Process Using FE Simulation and Experimental Work , 2005 .

[12]  Peter Hartley,et al.  Numerical simulation of single and dual pass conventional spinning processes , 2009 .

[13]  Hidetoshi Kotera,et al.  A study of the one-path deep drawing spinning of cups , 2005 .

[14]  Hui Long,et al.  Roller path design by tool compensation in multi-pass conventional spinning , 2013 .

[15]  Masujiro Hayama,et al.  The Fracture of Walls on Shear Spinning : Study on the Spinnability of Aluminium Plates , 1968 .

[16]  Hui Long,et al.  Investigation of material deformation in multi-pass conventional metal spinning , 2011 .

[17]  Chun-Ho Liu.  The simulation of the multi-pass and die-less spinning process , 2007 .

[18]  Hui Long,et al.  Analysis of conventional spinning process of a cylindrical part using finite element methods , 2008 .

[19]  Julian M. Allwood,et al.  Tool-path design for metal spinning , 2011 .

[20]  Hiroaki Kudo,et al.  Deformation Modes and Wrinkling of Flange on Shear Spinning , 1966 .

[21]  Hirohiko Arai.  Robotic metal spinning-shear spinning using force feedback control , 2003, 2003 IEEE International Conference on Robotics and Automation (Cat. No.03CH37422).

[22]  Xiao Gangfeng,et al.  A review of process advancement of novel metal spinning , 2014 .