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Experimental and numerical investigation of deformation characteristics during tube spinning

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A Correction to this article was published on 10 October 2020

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Abstract

The primary objective of this study is to predict the geometric shape and thickness change during multi-pass tube spinning to a hemispherical shape. A computationally efficient, axisymmetric finite element model of the tube-spinning experiments is described. Uniaxial tensile tests are conducted for the development of the material model. The post-necking hardening curve is identified using a hybrid experimental-numerical method and represented by a combined Swift-Voce model. For validation of the finite element model, spinning experiments are performed at room temperature on thin-walled cylinders of 6061-O aluminum alloy. The experiments are interrupted after spinning passes 2, 4, 6, and 8 and the shape and thickness are measured. Also, local strain measurements on the final spun tube (pass 8) are accomplished by a scribed grid. By comparing the predictions to the experiments, good agreement is obtained on the shape, thickness, and strain evolution in multi-pass spinning. The deformation mechanism of this process is described by analyzing the history of plastic strain on an element of the numerical model.

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Change history

  • 10 October 2020

    The original published article contained a mistake.

Abbreviations

β :

material parameter (Voce law)

ε 0 :

material parameter (Swift law)

ε θ :

hoop strain

\( \overline{\varepsilon_t^p} \) :

logarithmic plastic strain

η :

constant

λ :

constant

μ :

friction coefficient

σ t :

true stress

σ s :

true stress (Swift law)

σ v :

true stress (Voce law)

a :

weight ratio of hybrid Swift and Voce law

k 0 :

material parameters (Swift law)

l 0 :

material parameter (Voce law)

n :

material parameter (Swift law)

q :

material parameter (Voce law)

O :

annealing heat treatment condition

w 0 :

initial width of the 1/8th tensile specimen

w(y):

variation of width along axial direction

y :

axial (Cartesian coordinate system)

z :

axial (cylindrical coordinate system)

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Funding

This study received financial support from the Ministry of Education, Science, Sports, and Culture, of the Government of Japan.

Author information

Authors and Affiliations

  1. Graduate School of Science and Engineering, Saitama University, 255 Shimo-ohkubo, Sakura-ku, Saitama, 338-8570, Japan

    Biplov Kumar Roy

  2. Department of Integrated Systems Engineering, The Ohio State University, 234 Baker Systems, 1971 Neil Avenue, Columbus, OH, 43210-1271, USA

    Yannis P. Korkolis

  3. Division of Mechanical Engineering and Science, Graduate School of Science and Engineering, Saitama University, 255 Shimo-ohkubo, Sakura-ku, Saitama, 338-8570, Japan

    Yoshio Arai & Wakako Araki

  4. Asahi Seisakusho Co., Ltd., 7915 Kake, Iwatsuki-ku, Saitama City, Saitama, 339-0078, Japan

    Takafumi Iijima & Jin Kouyama

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  1. Biplov Kumar Roy
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Correspondence to Yannis P. Korkolis.

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Appendices

Appendix 1

This Appendix tabulates the coordinates of the roller during spinning (see Table 2).

Table 2 Roller position coordinate with spinning pass
Full size table

Appendix 2

This Appendix describes the comparison of results from the axisymmetric and a 3D shell element model. Due to the high computational time, only part of the first spinning pass was considered. A monitoring element at 50 mm from the free end (see Fig. 17) was selected in both models. Figure 18 compares the evolution of the hoop and meridional plastic strains during spinning. The models predict similar tendencies for the evolution of the strains, as well as a similar reduction in radius. On the other hand, the computational cost of the two models is vastly different: the corresponding solution times are listed in Table 3: the shell element model took approximately 500 times more to run than the axisymmetric one (i.e., approx. 10 days vs. 30 min). This is the reason why only the beginning of the spinning was simulated for this comparison. Furthermore, attempts to use the explicit solver for this problem were thwarted by numerical instabilities, at least for this high radius-to-thickness ratio of about 71. Therefore, in this work, the implicit axisymmetric model is used.

Fig. 17
figure 17

Spinning toolpath and monitoring element position

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Fig. 18
figure 18

History of hoop and meridional plastic strain changes with the roller axial position

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Table 3 FEA solution time
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Appendix 3

The simulation procedure that is executed by the commercial FE package ABAQUS is presented here. For simulation purposes, tube spinning is considered a quasi-static non-linear contact problem. Figure 19 presents the flow chart of the non-linear FE computational solution algorithm (Chapter 2, Section 2.2 in [39]). Figure 20 displays in more detail the flow chart of Coulomb friction algorithm, as used in ABAQUS (Chapter 5, Section 5.2.3 in [39]). Lastly, Fig. 21 shows the schematic that explains the geometric parameters associated with a contact pair involving a master (here, roller) and a slave (here, tube) surface.

Fig. 19
figure 19

Flow chart of non-linear FE solution algorithm for tube spinning simulation

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Fig. 20
figure 20

Flow chart of Coulomb friction algorithm for tube spinning simulation

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Fig. 21
figure 21

Schematic of tube spinning simulation contact (gap and penetration)

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Roy, B.K., Korkolis, Y.P., Arai, Y. et al. Experimental and numerical investigation of deformation characteristics during tube spinning. Int J Adv Manuf Technol 110, 1851–1867 (2020). https://doi.org/10.1007/s00170-020-05864-z

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