Numerical modelling, validation and analysis of multi-pass sheet metal spinning processes

Abstract

Conventional sheet metal spinning is an incremental forming process which typically involves the cost-effective and high-quality manufacturing of axissymmetric parts. The process is usually executed by highly skilled and experienced personnel which is able of optimizing the process parameters during production. Numerical simulation of the process can substantially help discovering systematic methodologies for optimal parameter determination and thus enable the full automation of the process using CNC machines. The present work aims to assess the quality of numerical modelling techniques by a direct comparison with metal spinning experiments. Based on the geometry and thickness distribution of intermediate and final stages of a spinned component, which are measured using the Optical 3D Digitization technique, the quality and validity of different numerical modeling approaches are assessed. Subsequently, deformation mechanisms occurring during process are identified, analysed and discussed.