Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis

Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two ‘designs of experiments’.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters.