REVERSE ENGINEERING OF THE METAL SPINNING PROCESS FOR CONICAL ANGLE 163° USING FEM WITH SIMUFACT FORMING

The process of metal spinning is performed based on years of experience and empirical research. For workpieces with complex shapes, this is a problematic and time-consuming task. The use of numerical studies is intended to ease the design of the metal spinning process. This article presents the results of shaping a conical product with an angle of 163° for two materials: AA 1050A and DC04 steel. The work under laboratory conditions was carried out using the MWS 200 machine. FEM simulations were performed in the Simufact Forming program. The testing methodology consisted of 4 consecutive stages. First, the spinning process was carried out with AA 1050A material. Second, boundary conditions were selected for FEM simulation. The third, spinning FEM tests were performed for DC04 steel. The fourth, metal spinning process tests were performed with DC04 steel. The influence of selected process parameters on the obtained product and the correlation with FEM studies are described. The results obtained showed that the discrepancy between laboratory and numerical tests is dependent on the material tested and its mechanical properties. In the case of aluminum, which is easier to form, it was possible to use an identical trajectory of the forming roll with an accuracy of 2.25%. As the mechanical parameters of the material increase, the differences between laboratory and numerical results increase. Consequently, a gap correction was necessary to achieve convergence. The value of the trajectory correction was determined by comparing the laboratory results obtained with the numerical results. The introduction of the correction resulted in a convergence between FEM and laboratory tests of 2.06%.