Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

  • Dawei Zhang
  • Fan Li
  • Shuaipeng Li
  • Shengdun Zhao
Research Article


Counter-roller spinning (CRS), where the mandrel is replaced by rollers, is an effective means of manufacturing large-sized, thin-walled, cylindrical parts with more than 2500 mm diameter. CRS is very complex because of multi-axis rotation, multi-local loading along the circumference, and radial-axial compound deformation. Analytical or experimental methods cannot fully understand CRS. Meanwhile, numerical simulation is an adequate approach to investigate CRS with comprehensive understanding and a low cost. Thus, a finite element (FE) model of CRS was developed with the FORGE code via meshing technology, material modeling, determining the friction condition, and so on. The local fine mesh moving with the roller is one of highlights of the model. The developed 3D-FE model was validated through a CRS experiment by using a tubular blank with a 720 mm outer diameter. The developed 3D-FE model of CRS can provide a basis for parameter optimization, process control, die design, and so on. The data on force and energy predicted by the 3D-FE model can offer reasonable suggestions for determining the main mechanical parameters of CRS machines and selecting the motors. With the predicted data, an all-electric servo-drive system/machine with distributed power was designed in this work for CRS with four pairs of rollers to manufacture a large-sized, thin-walled, cylindrical part with 6000 mm diameter.


large-sized cylindrical part counter-roller spinning aluminum alloy finite element method distributed power 


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This work was supported in part by the National Natural Science Foundation of China (Grant Nos. 51675415 and 51335009).


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Copyright information

© Higher Education Press and Springer-Verlag GmbH Germany, part of Springer Nature 2019

Authors and Affiliations

  • Dawei Zhang
    • 1
  • Fan Li
    • 1
  • Shuaipeng Li
    • 1
  • Shengdun Zhao
    • 1
  1. 1.School of Mechanical EngineeringXi’an Jiaotong UniversityXi’anChina

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