Simplified Three-Dimensional Finite Element Simulation of Shear Spinning Process Based on Axisymmetric Modeling

A simplified three-dimensional method for simulating plastic deformation in a shear spinning process of disks in a comparatively short computing time is proposed on the basis of the rigid-plastic finite element method using axisymmetric modeling. In this method, the shear spinning process is approximated as a forming process with a ringed die having the same cross-sectional shapes as the roller. The effects of the virtual shear deformation in the hoop direction and the incremental deformation in the shear spinning process are introduced into the axisymmetric modeling. A shear spinning process of disks having a taper flange is simulated by the proposed method. The forming limit is predicted from the pileup just before touching the roller in the finite element simulation. In addition, an actual shear spinning process of a large wheel disk for a bus and truck is simulated.