An experimental-numerical investigation of a metal spinning process

Spinning process is an advanced plastic working method, which is frequently used for manufacturing of axisymmetric shapes, especially those that cannot be easily produced with deep drawing method. In this article, a three-dimensional explicit finite-element (FE) analysis is employed to simulate the spinning process of an aluminium circular sheet. To achieve a wide range of strain distribution in different directions, a hemispherical cup has been chosen as the final product shape. In addition, a theoretical shear forming as well as a conventional model has been employed to estimate strain distribution in the spinning hemispherical cup. Experimental tests are carried out using a spinning machine and a hemispherical mandrel. Finally, FE and theoretical calculations are compared with the experimental results. A good agreement has been demonstrated between numerical and experimental results but a relative agreement with theoretical calculations.