Involute Curve Roller Trace Design and Optimization in Multipass Conventional Spinning Based on the Forming Clearance Compensation

In industrial production, the roller trace design is still based on the trial-and-error method that is more like an art than science. In this paper, we establish the mathematical model of the involute curve roller trace and adopted the forming clearance compensation in the attaching-mandrel process. The backward pass roller trace is optimized to avoid the roller interference due to blank springback. The spinning simulation model of seven forming passes is set up and verified by the experiments with superalloy GH3030. The wall thickness, the strain distribution, and the tool forces are analyzed. The results show that the forming clearance compensation can greatly shorten the forming time and enhance the production efficiency and saving energy. The metal accumulates at the edge of the blank, and the maximum thinning zone appeared near the edge and is prone to crack. In the straightening pass, the tool forces of both the roller and the mandrel are larger than those in the other passes.