3D FE modeling of the power spinning of complicated thin-walled shell

Some key technologies during the modeling process have been solved at the first, including the determination of initial position and roller path, and the implementation of the definition of blank thickness which is variable etc, and then based on software ABAQUS/Explicit, a 3D elastic- plastic dynamic explicit FEM model for the power spinning of complicated thin-walled shell has been established. Further, based on this model, metal accumulation has been found occurred easily at the frontage of the roller in the intermediate and final stage of the forming process, meanwhile the metal lies in behind of the roller being pulled to thinner. Especially, the wall thickness near the part opening reduces acutely. Finally, two methods have been proposed to avoid the metal accumulation and the excessive wall thickness reduction appearing in the forming process, by controlling the local thickness of the blank and controlling the clearance between roller and mandrel, respectively.