The simulation of the multi-pass and die-less spinning process

In the ending of the twenty century, the numerical simulations of metal forming are developed rapidly and widely, while the simulation of conventional spinning process still lacks detail compared to experimental work. One of the major reasons is the extremely dynamic contact conditions in the spinning process, the techniques of static-explicit FEM for the quasi-static forming process cannot handle spinning problems easily. This investigation applies the dynamic-explicit FEM code, LS-DYNA, to simulate the multi-pass and die-less spinning processes. With the applications of the mass scaling factor, contact algorithm, and adaptive control technique; reasonable results and some defects in the simulations are observed and discussed. The different variations in the feed rate of roller, direction of roller, and roller type were simulated. Effects on the predicted load-deformation relationship, the full history of deformation states and corresponding strain energy distributions are assessed. The suggested model is compared with experiment report, and shows a good availability for solving metal forming processes in the industrial works.