The Finite Element Method Appling in the Flow Forming

Spinning process of automotive drive housing part with spline, first, wafer material is chosen as billet. The billet is shaped by rolling depression using three rollers, and the roller is simulated by rigid model. The part material is extruded by three rollers to expand. Then it is shaped. By using simulation models in ABAQUS/Explicit, the spline shaping process of the part is simulated. After simulation, it can be seen that the interior of the part presents three-way compression stress and rim of the interior the local principal stretch. At the same time the spline shaping process is simulated by finite-element methods (FEM), it can be learned that partial part material flows forward, and the other material flows backward. When the feed rate of roller is high, main tendency is material flowing forward, whereas other material flows backward. When the feed rate of roller is low, main tendency is material flowing backward. In a word, suitable feed rate is contributive to shaping the spline. In order to make full use of material and make iner-spline´s teeth full, material flowing should be stopped at the end of the teeth. Finally, comparing simulation results with test results, it can be learned that they are basically in agreement. Therefore, the simulation example demonstrates the efficiency of finite-element methods used in spinning process of part.