Determination of the Optimal Rotational Speed of the Rollers in the Active Counter-Roller Spinning Process

Counter-roller spinning (CRS) is a crucial technology for the integrated shaping and strengthening of large, high-performance cylindrical components in aerospace. To address issues like buckling and torsional deformation in the formation of large-diameter, thin-walled cylinders, active counter-roller spinning (ACRS) is introduced. This method, which combines active rotation of both the rollers and the cylinder, significantly reduces torque and enhances forming accuracy. A comparison of the initial spinning torque T0 for a φ400 AA6061 alloy cylinder demonstrates that ACRS reduces torque by up to 93.73% compared to passive counter-roller spinning. This reduction decreases the power required for cylinder fixation. The study also identifies optimal roller speeds that align with the blank’s linear velocity in the forming zone, resulting in a substantial reduction in torque. At these speeds, straightness L and ovality O improve by 52.25% and 46.88%, respectively, offering valuable insights for refining CRS process.