Analysis of splitting spinning force by the principal stress method

The splitting spinning which is designed to split a rotational disk blank into two flanges, is one of newly rising, green flexible forming technologies, and it can be widely applied to manufacture a whole pulley or wheel in fields of aerospace, automobile and train. The investigation of forming parameters influencing on splitting spinning force can provide the foundation for the choice of equipments, the design of dies and the determination of processing parameters. This paper aims at developing a reasonable formula between splitting spinning force and forming parameters by the principal stress method, and then the reliability of the formula is verified by the comparisons with experimental data. Meanwhile, both a reasonable method of calculating the three-dimensional projected areas and a more effective method of solving the average angle in the deformation zone are presented. Furthermore, based on the formula, the laws of initial thickness and initial diameter of workpiece, diameter and splitting angle of splitting roller and feed ratio of splitting spinning influencing on splitting spinning force are investigated. The achievements may serve as an important guide for the determination and optimization of forming parameters of splitting spinning.