Application of Computationally Advanced 3D Finite Element Simulation for Stress and Strain Analysis of Single and Multi-pass Spinning Processes with Experimental Validation.

Throughout the plastic deformation of sheet metal axisymmetric shape parts such as hemispherical products using the spinning process, the sheet metal experiences intensive stresses and strains. Therefore, producing sheet metal pieces using this technique requires substantial skills. The study and analysis of stresses, strains, and other parameters affecting the process by means of numerical strategies or experimental setups help to better understand the stress–strain state and how the material is deformed during the process. In this study, a 3D finite element model is developed using Abaqus/Explicit solver to systematically analyze the spinning of hemispherical sheet metal parts in both single and multi-pass spinning operations and were compared with the results obtained from the experiments to confirm their validity. During the process, stresses, strains, and wall thickness distribution of the samples were investigated and compared with relevant experimental outputs. Also, the geometrical condition of the final product and applied forces to the workpiece were examined. The results obtained from the two operations (single-pass and multi-pass) indicate adequate consistency between the results of the simulation models and the experiments. [ABSTRACT FROM AUTHOR]