Three-dimensional finite element analysis of tube spinning

A three-dimensional elastic–plastic finite element model for three-roller backward spinning of a cylindrical workpiece is established and a practical spinning process of Hastelloy C alloy tube is simulated with the model and ANSYS software. The features of this model are as follows: (i) contact pairs are built up not only between the workpiece and rollers but also between the workpiece and the mandrel; (ii) the fixed end of the workpiece is constrained only in one axial direction, which is consistent with the practical spinning process; (iii) the rotation of the workpiece driven by the mandrel and the passive rotations of rollers due to the friction between the rollers and the workpiece are considered; (iv) the effect of the tip radius of the rollers is considered. The phenomena during tube spinning are simulated and analyzed with this model, such as bell-mouth, build-up, bulging in front of and between rollers, diametral reduction and growth. The simulation results correspond well to experiments.