Shear spinning: numerical modelling and process mechanics

Shear spinning is a bulk forming technique used to produce hollow, rotationally symmetric parts. Although the shear spinning process has been used for the last six decades in numerous industries, in the literature, the understanding of the mechanics of the process is limited. This study provides insight into process mechanics using physical trials and numerical models. Modelling the process is challenging because of the incremental nature of the process; existing numerical models in the literature suffer from lengthy computational times and simplifications. In this study, two numerical models with different approaches to the kinematics of the spinning process are modelled with input from tests to determine friction coefficient and material properties. Then they are validated against physical trials by comparing both part geometry and strain distribution. Validated numerical models are then employed to investigate the fundamental aspects of shear spinning mechanics; evolution of strains, roller forces and part geometry in a broad range of process conditions.