Finite Element Simulation of Metal Spinning: Influence of Rotational Speed on Stress, Forming Forces, and Product Quality.

  • Farooq, Aamir (KFUPM)
  • Albinmousa, Jafar (KFUPM)
  • Al-Badour, Fadi (KFUPM)

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Metal spinning is a highly versatile and efficient forming process used to manufacture axisymmetric components with minimal material waste. However, achieving optimal forming conditions remains a challenge due to the intricate interactions between process parameters. To address these complexities, computational modeling and simulation have become essential tools in analyzing and optimizing metal spinning processes. In this study, a finite element (FE) simulation of the metal spinning process was developed using Abaqus/Explicit to investigate the impact of rotational speed on stress distribution, forming forces, and geometrical accuracy. The material used is C11000 copper alloy, commonly employed in industrial applications for its excellent ductility and conductivity. The simulation was conducted for three different rotational speeds: 350, 477, and 750 rpm, while keeping other process parameters constant. A three-dimensional elastic-plastic model was implemented to simulate material deformation accurately. To ensure the reliability of the computational approach, the numerical results were compared with experimental data from published literature, demonstrating strong agreement with stress distribution trends and forming forces. The findings reveal that rotational speed significantly influences the stress distribution and overall geometrical quality of the final product. At lower speeds (350 rpm), non-uniform stress distribution led to wrinkling defects at the edges of the blank. Increasing the speed to 477 rpm resulted in a more uniform stress distribution, improving the final product's geometrical accuracy and reducing wrinkling. However, excessive stress concentration and severe wrinkling happened at 750 rpm, negatively affecting the surface quality. Similarly, forming force analysis indicated that higher rotational speeds reduce the overall forming force, with the total reaction force dropping from 40 kN at 477 rpm to 12 kN at 750 rpm. This reduction is attributed to an increase in the tangential force component, which facilitates material flow but may also lead to excessive thinning and defects. Additionally, strain distribution analysis along a radial path of nodes showed that higher rotational speeds enhance material plastic flow, increasing strain across the blank radius. This study highlights the effectiveness of finite element simulations in predicting process outcomes and guiding optimization strategies in advanced manufacturing.