Damage minimised ball spinning process design

Ball spinning is an incremental forming process for tubes and rods. The deformation of this process is limited by surface cracking. A closer look pointed out the dependence of some process parameters. The most influencing parameters are the workpiece diameter ratio D1/D2, the tool diameter ratio D1/d and the axial feed rate v. A vast number of experiments would be necessary to study all interactions between these parameters and a 3D FEM simulation would have limitations in the computing time. Hence, this investigation proposes a 2D FEM model to predict the damage during ball spinning and gives a detailed view into a statistical design of experiments. The results show a trend to increase the axial feed rate for a damage minimised process design.

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