Analysis and Modelling of the Deformation in the Manufacture of Flange-Contours by the Combined Friction-Spinning and Flow-Forming Process

This paper presents the extension, analysis and modelling of the deformation in the combined friction-spinning and flow-forming process using the example of the manufacture of flange contours, which is dominated by shear and tensile stresses in the tangential direction and by bending-like forming in the radial direction. With the aim of influencing these characteristic deformation mechanisms, the existing tool system was extended by an improved tool drive. The fundamental investigations on the influence of the increased tool rotation speed on the deformation were carried out using visio-plastic measurements. The key finding is that the velocity and direction of friction between the tool and the workpiece in interaction with the length of the path of friction is the major predictor of the twist angle and thus has a significant influence on shearing. It is shown that the twist angle can be adjusted by at least 105° using optimized parameters for the new tool system. Furthermore, enabling the defined adjustment of the twist angle a model has been built up and successfully validated. As a result, this enables a significant increase in the controllability of the deformation in this forming process and thus of the component properties, which lays the foundation for a significant expansion of the scope for defined residual stress adjustment in the friction-spinning process.