Modelling and Mechanics of Shear Spinning

Shear spinning is a bulk forming technique used to produce hollow, rotationally symmetric parts used in automotive, aerospace, nuclear and defence industry. The process has been invented about 60 years ago and is used widely in the industry. However, the literature and the understanding of process mechanics is limited. This paper investigates the process mechanics through a numerical model and a series of physical trials using commercially pure copper. The model is developed using commercial Finite Element software with input from tests to determine friction coefficient and material properties. It is then validated against physical trials comparing both part geometry and strain distribution in shear-spun parts. Validated model is then used to investigate mechanics of the process in terms of maximum equivalent plastic strain on the plate surface for different stages of the process and through thickness in three different sections. Also, another numerical model which has different kinematics has been developed to increase computation efficiency.