Forming characteristics of splitting spinning based on the behaviors of roller

The forming characteristics of splitting spinning based on the behaviors of roller is one important key of improvement of materials forming limit and forming precision. In this paper, the relationship between continuous feed conditions and feed amount of roller is obtained by the static analysis of splitting spinning. Based on the numerical relationship, the forming characteristics of splitting spinning based on the behaviors of roller is studied, including geometric parameter, boundary condition and contact. According to the above analysis of forming characteristics, a 3D elastic–plastic FE model of splitting spinning is established using the dynamic explicit FE code ABAQUS/Explicit, and then the reliability is proved by comparisons with experimental data. Furthermore, the influence laws of forming parameters of splitting spinning on the quality and precision of flanges are investigated under different forming conditions. The results are as follows: (1) On the conditions of 20 ⩽ α ⩽ 45° and r0 = 1.5 mm, deformed flanges satisfy high quality and high precision. (2) When feed rate 1.0 < v < 2.94 mm/s, thickness deviation changes comparatively even, probably holding from 10% to 20%, and when rotation speed of mandrels ω ⩽ 70 round/min, both the angle deviation of inner-face/outer-face goes towards zero. (3) The variation of friction coefficients between contact surfaces influencing on the degree of inhomogeneous deformation and thickness deviation of deformed flanges is notable, and influencing on the angle deviation is steady and even enough to obtain high quality and high precision. The forming characteristics of splitting spinning based on the behaviors of roller are revealed, and meanwhile the relative slip between roller and the workpiece and the non-uniform rotation and reverse rotation of roller may be avoided. The results may help to better understand the forming characteristics of splitting spinning based on the behaviors of roller and improve materials forming limit and forming quality.