Theoretical and experimental study of the effect of sheet thickness of aluminum 1435 on the final product quality and stress distribution in spinning sheet metal forming

Abstract EN

Spinning sheet metal forming (SSMF) has demonstrated a great potential to form a wide range of industrial products which have an axially symmetric shape.

This process produces a part with a good surface finish and high mechanical properties by using simple tools.

In this study, the deformation mechanics were investigated by using two approaches, theoretical and experimental.

The theoretical part included finite element models of cylindrical cups of Aluminum1435 using single roller passes and Finite Element code (ANSYS 15) were used to simulate the forming process and analysis the results theoretically.

The effect sheet thickness on the final product quality, stress distribution were studied.

The experimental study focused on the analysis of the shape accuracy produced by single pass metal spinning.

The numerical results were obtained in this study revealing that, failure by fracture is a predominant when a sheet with 1mm thickness is used, while failure by wrinkling was observed when a sheet with 2 mm thickness was used, the product with 3mm thickness showed no defects.

The experimental work included design and manufacturing of the forming tools can be fitted on the tool post of lathe after some modifications.

The results of the thickness variation along the cup wall was measured and compared with that obtained numerically.

The compared results showed a good agreement between them and the error percentage did not exceed 5.95%.