Finite Element Analysis and Investigation on Spinning of Quadrilateral Parts with Hollow Cross-Sections Based on Hypocycloid Theory

Abstract

This paper presents research on a new high-efficiency, non-circular spinning method based on hypocycloid theory. The trajectory of the roller during the forming process was derived, and the non-circular spinning process was simulated in ABAQUS 2016/Explicit. The distribution of von Mises stresses and equivalent plastic strains after each spinning pass were analyzed. The spinning quality was also investigated. This research proves the feasibility of spinning the workpieces of a non-circular cross-section using hypocycloid theory. This new non-circular spinning method can be used in practice to produce workpieces with a specific geometry and to increase the rotational speed of the workpiece from 60–240 rpm to 600 rpm, thereby improving the efficiency by around 2.5 times while maintaining acceptable forming quality.

Keywords

• non-circular spinning
• hypocycloid
• roller trajectory
• finite element simulation