Arbitrary Lagrangian–Eulerian Formulation in a Rotating Frame to Model Friction Spinning

ABSTRACT Friction spinning is a metal forming process that can be used to manufacture various shapes by rotating a metallic workpiece relative to a blunt tool. When used as a hot metal forming process, the relative velocity between workpiece and tool is increased until substantial heat is generated due to friction. This frictional heat softens the workpiece and allows it to be more readily shaped. However, the process's complex interactions between mechanical, frictional and thermal effects pose significant challenges for numerical modelling. The present study outlines a numerical model that uses the arbitrary Lagrangian–Eulerian (ALE) formulation in a rotating frame to simulate the friction spinning process. The key enabler is an incremental ALE formulation with reference‐velocity‐based remapping that allows for severe deformation and large rotational motion while preserving path‐dependent constitutive history variables. Proof‐of‐concept examples demonstrate its ability to simulate the upsetting of rods and rivets by friction spinning. The potential of the ALE formulation for modelling friction spinning is thereby confirmed, which paves the way for further research, model enhancements, parameter identifications and applications.