Abstract: Delving into the application of power spinning technology in the shaping of cylindrical components, examining the disparities in forming characteristics between ring rollers and conventional rollers, as well as their respective influences on the deformation behavior of the workpiece. An interference test was conducted to assess the geometrical differences in the deformation zones generated by the two types of roller during the forming process. Finite element analysis was employed to simulate the push power spinning processes for both types of rollers, providing a methodology for calculating the spinning force and analyzing the patterns of deformation zone states, loads on the rollers and mandrel. Additionally, the geometric features of the workpiece after push power spinning with both types of rollers were examined. The findings indicate that under the same forming conditions, the application of push power spinning with ring rollers produced greater loads, and the forming process exhibited a more significant compressive stress state and a smaller gradient of equivalent plastic strain. The specific experimental outcomes are detailed as follows: under equivalent reduction conditions, the ring roller increased the interference wrap angle by approximately 1.5 times; the roller and mandrel experienced higher loads during the push power spinning, approximately 1.5 times greater than those observed in the traditional rollers; the stress triaxiality induced by the ring roller in push power spinning was found to be lower and more uniform, with the maximum differences in stress triaxiality at positions R16, R17, and R18 being 0.55, 0.39, and 0.74, respectively; the springback after forming with the ring roller was approximately 0.15 mm, which is about 43% of that observed with traditional roller (0.35 mm), and the uniformity of wall thickness was superior; the circumferential wall thickness error of the workpiece obtained through ring roller spinning was less than 0.001 mm; the ring roller facilitated the torsional deformation of the workpiece and improved the uniformity of the torsion.

Key words: push power spinning, roller structure, stress triaxiality, finite element analysis, load