Investigation of dimensional accuracy in spinning process using experimental work and FE simulation

Spinning process recently became an advanced plastic working technology and is used for manufacture some axisymmetric parts. To begin a manufacturing process, first, a metal blank is fixed on the mandrel that clamped on the spindle. Then the blank with the spindle start rotating at a high speed causes the blank to be formed and converted into an axisymmetric part by using a roller, which gradually pushes the blank against a mandrel. In this paper, to find the effect of main process parameters such as tool feed rate, mandrel rotational velocity and feed ratio (the ratio of tool feed rate to mandrel rotational velocity) on the dimensional accuracy (due to spring-back) of Al-6061-O conical parts, an experimental investigation and finite element analysis were performed. Finally, a comparison between the experimental and numerical results was undergone and found a good agreement between them. It was observed that as the feed rate increases and rotational velocity decreases, the inside diameter will be increased. There was also no change in the dimensional accuracy when the feed ratio remains constant.