Abstract
Conventional spinning is a kind of ancient revolving process which controls the product’s shape by roller trace design. It is also widely used in civil, military, automobile, aerospace and other fields. Unlike the power spinning process, the roller trace used in conventional spinning is complex. Both thickness uniformity and crack defects are affected by it. However, roller trace design is still based on experience without a solid theoretical basis. This paper simulated five different roller trace curves: involute curve, circular curve, Bezier curve, conchoids and line. Experiments using superalloy GH3030 were conducted in conjunction with a multi-pass conventional spinning simulation model. Blank thickness variations, mandrel and roller forces of different roller traces in the first pass are analyzed and assessed through the verification experiments. The results suggest that the curve trace parameters play a key role on the product thickness uniformity. And the distribution of Bezier and conchoid roller traces is more uniform than the other traces. The axial force of mandrel is a very important factor in the design of tool load capability. Larger roller feed ratio and proper roller traces can reduce the thinning which may avoid the cracks.