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

  • Chengcheng ZhuEmail author
  • Shengdun Zhao
  • Shuaipeng Li
  • Shuqin Fan


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.


Mandrel spinning Counter-roller spinning Spinning theory Finite element method 


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Funding information

This work was supported by the Science and Technology Coordination Innovation Project of Shaanxi Province [grant number 2011KTCQ01-04] and the State Key Laboratory for Mechanical Behavior of Materials [grant number 1991DA105206].

Compliance with Ethical Standards

Conflict of interest

The authors declare that they have no conflicts of interest.


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.School of Mechanical EngineeringXi’an Jiaotong UniversityXi’anChina
  2. 2.Department of Mechanical EngineeringNational University of SingaporeSingaporeSingapore

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