Comparison of mandrel and counter-roller spinning methods for manufacturing large sheaves

摘要

A number of spinning methods can be utilized to produce large sheaves such as crosshead sheaves. However, few studies have investigated the relationship and differences between these methods. Therefore, an exploration of spinning features is necessary. In this study, four typical spinning methods, including a novel counter-roller spinning method, were selected to study the forming process. Numerical simulation and experiment study were performed. A theoretical model was then proposed to determine the differences between each spinning method. Stress and strain distribution, thickness reduction, and spinning forces during the forming process were obtained, and results of the simulations and experiments matched well. Variations in the sheave thickness, stress value, and spinning force were observed with different spinning methods. Although all spinning methods investigated in this study could form sheaves, counter-roller spinning with a simple roller method demonstrated the smallest thickness reduction, spinning force, and forming stress. Therefore, the counter-roller spinning should be the first option for spinning large sheaves.