Experimental and numerical investigation of deformation characteristics during tube spinning
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ORIGINAL ARTICLE
Experimental and numerical investigation of deformation characteristics during tube spinning Biplov Kumar Roy 1 & Yannis P. Korkolis 2
&
Yoshio Arai 3 & Wakako Araki 3 & Takafumi Iijima 4 & Jin Kouyama 4
Received: 20 April 2020 / Accepted: 31 July 2020 / Published online: 29 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The primary objective of this study is to predict the geometric shape and thickness change during multi-pass tube spinning to a hemispherical shape. A computationally efficient, axisymmetric finite element model of the tube-spinning experiments is described. Uniaxial tensile tests are conducted for the development of the material model. The post-necking hardening curve is identified using a hybrid experimental-numerical method and represented by a combined Swift-Voce model. For validation of the finite element model, spinning experiments are performed at room temperature on thin-walled cylinders of 6061-O aluminum alloy. The experiments are interrupted after spinning passes 2, 4, 6, and 8 and the shape and thickness are measured. Also, local strain measurements on the final spun tube (pass 8) are accomplished by a scribed grid. By comparing the predictions to the experiments, good agreement is obtained on the shape, thickness, and strain evolution in multi-pass spinning. The deformation mechanism of this process is described by analyzing the history of plastic strain on an element of the numerical model. Keywords Tube spinning . Toolpath design . Axisymmetric modeling . AA6061-O
1 Introduction Tube spinning is one of the most common incremental forming processes. The process has some distinct advantages over other metal forming processes, such as no need for dies and/or mandrel, smaller deformation forces, and shorter production time in comparison to other incremental forming processes [1–3]. An extensive assessment of this process regarding essential aspects and recent developments can be found in previous review papers [2, 3]. Recently, there is interest in
* Yannis P. Korkolis [email protected] Biplov Kumar Roy [email protected]
utilizing tube spinning to produce large-scale, dimensionally precise axisymmetric products like a seamless, pressurized, thin-walled spherical fuel tank for a rocket. In comparison to the current state-of-art, the objective of this work is to contribute to the spinning of a large, thin-walled sphere (thickness-todiameter ratio of less than 0.01) from an aluminum tube, avoiding excessive trial-and-error experiments through the use of numerical simulation. Plastic flow in tube spinning is highly localized, rotary, and incremental and is generated by contact with a tool, typically
1
Graduate School of Science and Engineering, Saitama University, 255 Shimo-ohkubo, Sakura-ku, Saitama 338-8570, Japan
2
Department of Integrated Systems Engineering, The Ohio State University, 234 Baker Systems, 1971 Neil Avenue, Columbus, OH 43210-1271, USA
3
Division of Mechanical Engineering and Science, Graduate School of Scienc
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