Three-dimensional finite element analysis of effects of roller intervals on tool forces and wall thickness in stagger spinning of thin-walled tube

摘要

Roller intervals are the key parameters of the stagger spinning process, which affect the shape accuracy and productivity of the products. In this article, the effects of different roller intervals in axial and radial directions on tool forces, wall thickness, and strain and stress variations in stagger spinning have been analyzed numerically by the finite element analysis. The results show that with the increasing of the axial roller intervals, the differences between tool force components (axial, radial, and tangential) become lower at first, and then have the trend to be higher. The similar phenomenon on tool force occurs when the radial interval of roller 3 increases and that of roller 2 decreases. Wall thickness variations are mainly affected by axial roller intervals; the bigger the axial intervals are, the higher the variations of wall thickness that would be seen. Meanwhile, the real reductions of wall thickness are mainly affected by radial roller intervals. When the radial interval of roller 3 is larger than that of roller 2, there would be a higher real wall thickness reduction.