Abstract: “In the recent decades, multi-pass sheet metal spinning proved to be a critical process for many industrial components such as jet engines, large size pressurized tanks and vessels, but residual stresses and springback in these spun parts remain an alarming problem. This study is intended to provide wider insight into the controlling parameters of these features. Two finite element (FE) simulations were conducted based on explicit code for the spinning process and implicit code for springback and residual stresses prediction. The numerical results were verified and found to be well correlated with the experimental data. Optimum combination between small springback and safety against residual stresses was obtained using low feed ratio and friction coefficient with large number of spinning passes. The common issue is low loading rate. Better control of the final spinning pass can add value to the mechanical and dimensional characteristics of the spun component.”

Keywords: Multi-pass sheet metal spinning, Residual stresses, Springback, Finite element analysis, Pressure vessels