A method based on circumferential strain distribution for roller path design in conventional spinning of thin-walled conical part with curved surface

Multi-pass conventional spinning is the preferable forming technology for the forming of thin-walled conical part with curved surface (TCPCS) in aerospace field. In multi-pass conventional spinning, the design of roller path is a critical problem due to its sensitive effect on the deformation mode and forming defect during spinning process. However, at present, the roller path is still mainly designed based on experience and trial-and-error, which seriously restricts the high-performance spinning of TCPCS. In this work, a new quantitative method based on circumferential strain distribution was developed for the roller path design in multi-pass conventional spinning of TCPCS. In this method, the total required circumferential strain for the forming of final TCPCS by conventional spinning was firstly determined. Then, the spinning passes number were obtained through dividing the total required circumferential strain by the ultimate circumferential strain producing the spinning instability ( ε θult ). As for the roller path profile in each pass, it is divided into two sections and determined respectively, i.e. the attaching mandrel section and the performing section. The attaching mandrel section presents the same profile of mandrel. The profile of preforming section is determined point-by-point by distributing the rest of circumferential strain { ε θni } to produce the final TCPCS. The point-by-point distributed circumferential strain is half of the { ε θni } at the initial stage until reaches the half of ε θult , then it will keep the half of ε θult to the end. The proposed new method of roller path design was validated by finite element simulation, where well spinning stability, wall thickness distribution and roundness were obtained. This method provides a quantitative, high-efficient and universal way for the roller path design in conventional spinning of TCPCS.