Research on influences of roller parameters on splitting spinning of aluminum alloy

Splitting spinning of aluminum alloy is a much complex plastic process with multi-factors coupling interactive effects. The analysis of influences of roller parameters on the forming process may provide an important guide for determining the forming parameters and the optimum design of splitting spinning of aluminum alloy. Based on the established reliable 3D-FE model of splitting spinning of aluminum alloy, the influences of roller parameters, including splitting angle, radius of corner and feed ratio of roller, on the variations of the tangential stress, circumferential stress and inhomogeneous deformation and final thickness deviation of deformed flanges have been revealed. The results shows that: the increase of splitting angle of roller may eliminate the metal accumulation in front of roller, decrease the possibility of material failure and reduce inhomogeneous deformation and forming precision; the influences of radius of corner of roller on the metal accumulation in front of roller and the possibility of material failure are not obvious, and the increase of radius of corner of roller may increase inhomogeneous deformation and forming precision; and the influences of feed ratio of roller on the metal accumulation in front of roller and forming precision are not obvious, and the increase of feed ratio of roller may decrease the possibility of material failure and reduce inhomogeneous deformation.