The Effect of Forming Diameter and Rotational Speed on Characterization of Formed Tubes by Spinning Process

Authors

Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran

10.22044/jsfm.2025.16131.3969

Abstract

The spinning process is a common forming process used in the production of various products. It involves shaping sheets and tubes to create industrial products and sizing the connections in tubes. The purpose of this research is to investigate the effects of the final forming diameter and rotational speed on the twist angle, microstructure, hardness, strength, and the weldability in the spinning process of tubes. The spinnig process was analytically and experimentally evaluated, and the results were investigated using ANOVA analysis. The experiments were conducted using three different diameters and rotational speeds, and the response surface method was used to design the experiments. The analysis of the results revealed that the final forming diameter, or plastic strain, has a significantly greater effect on the mechanical properties and microstructure of the material compared to the rotational speed. An increase in rotational speed and forming diameter leads to a greater twist angle in the tubes. Higher rotational speeds and plastic strain result in increased contact and frictional forces, which cause the temperature to rise within the specimens. Increasing temperature results in grain growth, reduced work hardening, and consequently, a decrease in the material's strength and hardness. At a constant speed, a 25% increase in diameter results in a 47% decrease in hardness and strength. Additionally, using a rotational speed of 1000 rpm and a final diameter of 18 mm can increase the grain size up to three times the initial value and produce a maximum twist angle of 48⁰ in the sample.

Keywords

Main Subjects

References

  • Golmakani H., Dadgar Asl Y. and Seyedkashi S. M. H. (2024) Numerical and Experimental Analysis of Bowing Defect in the Flexible Roll Forming Process of Copper-Aluminum Double Layer Sheets. J. Solid Fluid Mech. 13(6): 75-87.
  • Elyasi M., Modanloo V., AhmadKkhatir F. and Talebi-Ghadikolaee H. (2023) Experimental investigation of the formability of heat treated AA6063 tubes using hydraulic rotary draw bending process. J. Solid Fluid Mech. 13(4): 95-106.
  • Wong C., Dean T. and Lin J. (2003) A review of spinning, shear forming and flow forming processes. J. Mach. Tools Manuf. 43(14): 1419-1435.
  • Groover M. P. (2010). Fundamentals of modern manufacturing: materials, processes, and systems, John Wiley & Sons.
  • Music O., Allwood J. and Kawai K. (2010) A review of the mechanics of metal spinning. J. Mater. Process. Technol. 210(1): 3-23.
  • Abd-Alrazzaq M., Ahmed M. H. and Younes M. A. (2019). Prediction of Residual Stresses and Springback in Multi-pass Sheet Metal Spinning Using Finite Element Analysis. Proc. Eighth Int. Conf. Adv. Civ. Struct. Mech. Eng. Egypt: 90-105.
  • Shu X., Chang Y., Zhu Y., Ye B. and Li Z. (2020) Production mechanism of residual stress in spinning of thin wall cone parts with variable section. Procedia Manufacturing 50: 286-290.
  • Zixuan L. and Xuedao S. (2022) Residual stress analysis of multi-pass cold spinning process. Chin. J. Aeronaut. 35(3): 259-271.
  • Dahms F. and Homberg W. (2022) Manufacture of defined residual stress distributions in the friction-spinning process: investigations and run-to-run predictive control. Metals 12(1): 158.
  • Li L., Chen S., Lu Q., Shu X., Zhang J. and Shen W. (2023) Effect of Process Parameters on Spinning Force and Forming Quality of Deep Cylinder Parts in Multi-Pass Spinning Process. Metals 13(3): 620.
  • Sedighi M. and Naserinejad K. (2021) Feed effect on strain and stress in dome forming (spinning) of a tube in an aluminum CNG vessel manufacturing J. Appl. Comput. Sci. Mech. 32(2): 43-60.
  • Huang C.-C., Hung J.-C., Hung C. and Lin C.-R. (2011) Finite element analysis on neck-spinning process of tube at elevated temperature. Int. J. Adv. Manuf. Technol. 56: 1039-1048.
  • Nakasato S., Kobayashi J. and Itoh G. (2018) Hot spinning formability of aluminum alloy tube. Procedia Manufacturing 15: 1263-1269.
  • Roy B. K., Korkolis Y. P., Arai Y., Araki W., Iijima T. and Kouyama J. (2020) Experimental and numerical investigation of deformation characteristics during tube spinning. Int. J. Adv. Manuf. Technol. 110: 1851-1867.
  • Li Y., Wang J., Lu G.-d. and Pan G.-j. (2014) A numerical study of the effects of roller paths on dimensional precision in die-less spinning of sheet metal. J. Zhejiang Univ. Sci. A 15(6): 432-446.
  • Rentsch B., Manopulo N. and Hora P. (2017) Numerical modelling, validation and analysis of multi-pass sheet metal spinning processes. Int. J. Mater. Form. 10: 641-651.
  • Abd-Alrazzaq M., Ahmed M. and Younes M. (2018) Experimental investigation on the geometrical accuracy of the CNC multi-pass sheet metal spinning process. J. Manuf. Mater. Process. 2(3): 59.
  • Huang J., Jin J., Deng L., Wang X., Gong P., Zhang M. and Gao C. (2021) Theoretical prediction of flange wrinkling in the first-pass conventional spinning of dual-metal sheets. J. Manuf. Process. 62: 368-377.
  • Gondo S., Arai H., Kajino S. and Hanada K. (2022) Evolution of texture distribution in thickness direction of aluminum sheet in metal spinning. Mater. Charact. 188: 111877.
  • Gao P., Yan X., Li F., Zhan M., Ma F. and Fu M. (2022) Deformation mode and wall thickness variation in conventional spinning of metal sheets. Int. J. Mach. Tools Manuf. 173: 103846.
  • Zhuolei Z., Mei Z., Zhipeng S., Yunda D. and Xiaoguang F. (2024) Acceleration of sheet metal spinning simulation by multi-mesh method. Chin. J. Aeronaut.
  • ASTM E.-. (2004). Standard test methods for determining average grain size. West Conshohocken, PA, USA, ASTM International.
  • Krishna S. C., Gangwar N. K., Jha A. K. and Pant B. (2013) On the prediction of strength from hardness for copper alloys. J. Mater. 2013(1): 1-6.

 

  • Hosford W. F. and Caddell R. M. (2011). Metal forming: mechanics and metallurgy, Cambridge university press.
  • Molotnikov V. and Molotnikova A. (2021). Theory of elasticity and plasticity, Springer.
  • Callister Jr W. D. and Rethwisch D. G. (2020). Materials science and engineering: an introduction, John wiley & sons.
  • Zheng F., Chen H., Zhang Y., Wang W., Nie H., (2022) Microstructure evolution and corrosion resistance of AZ31 magnesium alloy tube by stagger spinning. Int. J. Miner. Metall. Mater. 29(7): 1361-1372.
  • Jin K., Yuan Q., Tao J., Domblesky J. and Guo X. (2019) Analysis of the forming characteristics for Cu/Al bimetal tubes produced by the spinning process. Int. J. Adv. Manuf. Technol. 101: 147-155.
  • Rezaei Ashtiani H. R. and Deilami Azodi H. (2021) Experimental investigation of the effect of processing parameters on mechanical properties and dimensional changes of warm flow formed 6061 aluminum alloy tube. Modares Mech. Eng. 21(7): 489-499.
  • Music O. and Sariyarlioglu E. C. (2022) Mechanics of tube spinning: a review. Int. J. Adv. Manuf. Technol. 123(3): 709-735.
  • Zheng J., Zixuan L., Xuedao S., Haijie X., Tangjian X. (2024) Tube spinning process: Recent advances and challenges. J. Adv. Manuf. Sci. Technol. 4(4).
Journal of Solid and Fluid Mechanics
Volume 15, Issue 5
November and December 2025
Pages 367-376

Files

Share

How to cite

Statistics