Forming quality of the first pass spinning of large-sized complicated thin-walled shell

To optimize the process parameters of the first pass spinning of large-sized complicated thin-walled shell, based on the platform of ABAQUS, a solid finite element (FE) model has been established; the field outputs related to solid element model, including the wall thickness and the fittability, have been achieved by the second-develop; and the effects of blank diameter and the interaction between deforming area and other areas on the power spinning of the large-sized cone has been investigated. By using the orthogonal experimental design (OED), the effects of processing parameters on the forming quality of the large-sized cone and the optimized parameters are obtained. The results show that the gap between the roller and the mandrel is the most important parameter for the process; the forming quality at near zero deviation is the best; a larger roller nose radius is helpful to decrease the possibility of local destabilization and fracture; and a larger roller feeding can benefit for improving the wall thickness precision of the large-sized cone and also can decrease the possibility of local destabilization during the process.