The Iraqi Journal For Mechanical And Material Engineering, Vol.

16, No3, 2016

THEORETICAL AND EXPERIMENTAL STUDY OF THE

EFFECT OF SHEET THICKNESS OF ALUMINUM 1435 ON
THE FINAL PRODUCT QUALITY AND STRESS
DISTRIBUTION IN SPINNING SHEET METAL FORMING
Abdul Kareem Jalil Kadhim and Ali Sadik Gaffer
Babylon University, College of Engineering, Mechanical Eng. Dept., drkreem959@yahoo.com
Babylon University, College of Engineering, Mechanical Eng. Dept., alialseide@gmail.com

ABSTRACT :
Spinning sheet metal forming (SSMF) has demonstrated a great potential to form a wide
range of industrial products which have an axially symmetric shape. This process produces a
part with a good surface finish and high mechanical properties by using simple tools. In this
study, the deformation mechanics were investigated by using two approaches, theoretical
and experimental. The theoretical part included finite element models of cylindrical cups of
Aluminum1435 using single roller passes and Finite Element code (ANSYS 15) were used
to simulate the forming process and analysis the results theoretically. The effect sheet
thickness on the final product quality, stress distribution were studied. The experimental
study focused on the analysis of the shape accuracy produced by single pass metal spinning.
The numerical results were obtained in this study revealing that, failure by fracture is a
predominant when a sheet with 1mm thickness is used, while failure by wrinkling was
observed when a sheet with 2 mm thickness was used, the product with 3mm thickness
showed no defects. The experimental work included design and manufacturing of the
forming tools can be fitted on the tool post of lathe after some modifications. The results of
the thickness variation along the cup wall was measured and compared with that obtained
numerically. The compared results showed a good agreement between them and the error
percentage did not exceed 5.95%.
KEYWORDS: spinning, forming, sheet thickness, numerical simulation.

‫ ﻋﻠﻰ ﺟﻮدة اﻟﻤﻨﺘﺞ اﻟﻨﮭﺎﺋﯿﺔ‬1435 ‫دراﺳﺔ ﻧﻈﺮﯾﺔ وﻋﻤﻠﯿﺔ ﻟﺘﺄﺛﯿﺮ ﺳﻤﻚ اﻟﺼﻔﯿﺤﺔ اﻷﻟﻤﻨﯿﻮم‬
‫وﺗﻮزﯾﻊ اﻻﺟﮭﺎدات ﻋﻨﺪ ﺗﺸﻜﯿﻞ اﻟﺼﻔﺎﺋﺢ اﻟﻤﻌﺪﻧﯿﺔ ﺑﺎﻟﺮﺣﻮ‬
: ‫اﻟﺨﻼﺻﺔ‬
‫اﺛﺒﺖ ﺗﺸﻜﯿﻞ اﻟﺼﻔﺎﺋﺢ اﻟﻤﻌﺪﻧﯿﺔ ﺑﺎﻟﺮﺣﻮ إﻣﻜﺎﻧﺎت ﻛﺒﯿﺮة ﻟﺘﺸﻜﯿﻞ ﻣﺠﻤﻮﻋﺔ واﺳﻌﺔ ﻣﻦ اﻟﻤﻨﺘﺠﺎت اﻟﺼﻨﺎﻋﯿﺔ اﻟﺘﻲ ﻟﮭﺎ ﺷﻜﻞ‬
‫ ﻓﻲ ھﺬه‬.‫ ﺗﻨﺘﺞ ھﺬه اﻟﻌﻤﻠﯿﺔ ﺟﺰء ذو اﻧﮭﺎء ﺳﻄﺤﻲ ﺟﯿﺪ واﻟﺨﻮاص اﻟﻤﯿﻜﺎﻧﯿﻜﯿﺔ ﻋﺎﻟﯿﺔ ﺑﺎﺳﺘﺨﺪام أدوات ﺑﺴﯿﻄﺔ‬.‫ﻣﺘﻤﺎﺛﻞ ﻣﺤﻮرﯾﺎ‬
‫ اﻟﺠﺰء اﻟﻨﻈﺮي ﺗﻀﻤﻦ ﻧﻤﺎذج اﻟﻌﻨﺎﺻﺮ اﻟﻤﺤﺪدة‬.‫اﻟﺪراﺳﺔ ﺗﻢ اﻟﺘﺤﻘﯿﻖ ﻓﻲ ﻣﯿﻜﺎﻧﯿﻜﯿﮫ اﻟﺘﺸﻮه ﺑﺎﺳﺘﺨﺪام ﻧﮭﺠﯿﻦ ﻧﻈﺮي وﻋﻤﻠﻲ‬
‫ ﺑﺎﺳﺘﺨﺪام ﻣﻤﺮات اﻟﺮوﻟﺔ اﻷﺣﺎدﯾﺔ وﺗﻢ اﺳﺘﺨﺪام ﺑﺮﻧﺎﻣﺞ ﺧﺎص ﺑﺘﻘﻨﯿﺔ اﻟﻌﻨﺎﺻﺮ‬1435 ‫ﻟﻠﻜﺆوس اﻷﺳﻄﻮاﻧﯿﺔ ﻟﻸﻟﻤﻨﯿﻮم‬
‫ ﺗﻤﺖ دراﺳﺔ ﺗﺄﺛﯿﺮ ﺳﻤﻚ اﻟﻌﯿﻨﺔ ﻋﻠﻰ ﺟﻮدة اﻟﻤﻨﺘﺞ‬.‫( ﻟﻤﺤﺎﻛﺎة ﻋﻤﻠﯿﺔ اﻟﺘﺸﻜﯿﻞ وﺗﺤﻠﯿﻞ اﻟﻨﺘﺎﺋﺞ ﻧﻈﺮﯾﺎ‬ANSYS15) ‫اﻟﻤﺤﺪدة‬
. ‫رﻛﺰت اﻟﺪراﺳﺔ اﻟﻌﻤﻠﯿﺔ ﻋﻠﻰ ﺗﺤﻠﯿﻞ دﻗﺔ اﻟﺸﻜﻞ اﻟﻨﺎﺗﺞ ﺑﺎﻟﺮﺣﻮ اﻟﻤﻌﺪﻧﻲ ﺑﺎﺳﺘﺨﺪام اﻟﻤﺴﺎر اﻟﻮاﺣﺪ‬. ‫اﻟﻨﮭﺎﺋﯿﺔ وﺗﻮزﯾﻊ اﻻﺟﮭﺎدات‬
‫ﻛﺸﻔﺖ اﻟﻨﺘﺎﺋﺞ اﻟﻌﺪدﯾﺔ اﻟﺘﻲ ﺗﻢ اﻟﺤﺼﻮل ﻋﻠﯿﮭﺎ ﻓﻲ ھﺬه اﻟﺪراﺳﺔ أن اﻟﻔﺸﻞ ﺑﺎﻟﻜﺴﺮ ھﻮ اﻟﺴﺎﺋﺪ ﻋﻨﺪ اﺳﺘﺨﺪام ﻋﯿﻨﮫ ﺳﻤﻜﮭﺎ‬
.‫ ﻻ ﯾﻈﮭﺮ ﻋﯿﻮب‬3mm‫ اﻟﻤﻨﺘﺞ ﻣﻊ ﺳﻤﻚ‬،2mm ‫ ﻓﻲ ﺣﯿﻦ ﻟﻮﺣﻆ ان اﻟﻔﺸﻞ ﺑﺎﻟﺘﺠﺎﻋﯿﺪ ﻋﻨﺪ اﺳﺘﺨﺪام ﻋﯿﻨﮫ ﺳﻤﻜﮭﺎ‬، 1mm
‫ﺗﻀﻤﻦ اﻟﻌﻤﻞ اﻟﺘﺠﺮﯾﺒﻲ ﺗﺼﻤﯿﻢ وﺗﺼﻨﯿﻊ اﻻت اﻟﺘﺸﻜﯿﻞ واﻟﺘﻲ ﯾﻤﻜﻦ اﺳﺘﺨﺪاﻣﮭﺎ ﻋﻠﻰ ﻣﻘﻠﻤﮫ اﻟﻤﺨﺮطﺔ ﺑﻌﺪ اﺟﺮاء ﺑﻌﺾ‬
‫أظﮭﺮت‬. ‫ وﻗﺪ ﺗﻢ ﻗﯿﺎس اﺧﺘﻼف اﻟﺴﻤﻚ ﻋﻠﻰ طﻮل ﺟﺪاراﻟﻜﺄس وﻣﻘﺎرﻧﺘﮭﺎ ﻣﻊ ﺗﻠﻚ اﻟﺘﻲ ﺗﻢ اﻟﺤﺼﻮل ﻋﻠﯿﮭﺎ ﻋﺪدﯾﺎ‬.‫اﻟﺘﻌﺪﯾﻼت‬
.٪5.95 ‫ﻧﺘﺎﺋﺞ اﻟﻤﻘﺎرﻧﺔ ﺗﻘﺎرب ﺟﯿﺪ ﺑﯿﻨﮭﺎ و ﻧﺴﺒﺔ ﺧﻄﺄ ﻻ ﺗﺘﺠﺎوز‬

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THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

1- INTRODUCTION :

SSMF is one of the metal forming operations, where a flat metal blank is formed by a roller
which gradually forces the blank on the mandrel, to form the final shape of the product.
Through the spinning process, the blank is clamped between the mandrel and tail stock, these
three components rotate synchronously at a predetermined spindle speed as shown in Fig.1.
[Runge 1994]. [Liu 2002] obtained the distributions of radial, hoop and thickness stresses of a
conventional draw spinning in the first pass of the process under three types of roller race
curves (straight lines, involute curves and quadratic curves) with an Elasto Plastic Finite
Element Method. [Kleiner2002] selected possible input factors in their factorial experiments
in order to identify the effects of key process parameters on the wrinkling failure in the
spinning. These factors included the thickness of the blank and the axial feed of the roller
tool. [Xia 2005] studied one path spinning of mild steel and pure aluminum cups
experimentally. Forming conditions considered in their research included the thickness which
was found to be important parameters affecting the spinning force, nominal thickness strain
and material formability. [Sebastiani, 2007] presented Finite Element Analysis by means of
the explicit code LS-DYNA. They used the mild steel (DC04) as circular blank. They
concluded that the compressive stresses in the roller-facing and tensile stresses in the
mandrel-facing surface. [Long and Hamilton2008] proposed the simulation of the forming of
a cylindrical spun part by the single pass of a roller using FE dynamic explicit formulations.
The results show that the non-uniformly distributed radial and hoop strains have a decisive
effect on the variation of the thickness strain. [Essa and Hartley 2010] used the design of
experiments (DOE) approach for generating experimental plan and conducted numerical
simulation of the cylindrical cup. They assessed the results using the ANOVA technique to
identify the most critical working parameters. They observed that the feed rate and roller nose
radius were the most critical variables affecting ability of forming without wrinkling, also the
initial sheet diameter, whilst important, had less effect and friction coefficient had no
observable effect upon the process formability. [Hamilton and Long 2010] studied the
material deformation mechanism and typical cases of material failure in conventional metal
spinning. The development of explicit FE simulation models of a spun cylindrical part by a
single-pass of the roller was reported. They observed necking around the filleted mandrel
edge and thickening towards the part opening. The results show that wrinkling defects have
been demonstrated at higher feed rates, although these effects may be exaggerated by the use
of shell elements. [Wang 2010] carried out a one-pass spinning experiment with three factors
varying at two levels by applying the Taguchi method. The experimental results also showed
that using higher feed rates and low spindle speeds it resulted in a smaller reduction of wall
thickness. [Wang and Long 2011] designed four different roller path profiles (linear, convex,
concave and combined convex and concave). They studied numerically the effects of these
roller paths on tool forces and part wall thickness in conventional metal spinning. The results
showed that the concave path produces highest tool forces among these four roller path
profiles and higher reductions of wall thickness of the product. Using the convex roller path,
assisted in maintaining the original wall thickness unchanged. [Wang and Long 2013]
proposed tool compensation technique in multiple roller passes design in conventional
spinning. They applied Taguchi method and analyzed the effects of material type, feed ratio

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Ali S. Gaffer

on the dimensional variations of the spun parts. They used finite element simulation to
investigate the variations of tool forces and wall thickness High feed ratios can help to
maintain the original wall thickness unchanged, but cracking failures may occur if a larger
feed ratio was applied. Comparing with aluminum, mild steel has a better ability to stand
cracking failures in the conventional spinning process. They observed that the axial force is
the highest and the tangential force is the lowest and the wall thickness of the work piece
decreases gradually after each forward roller pass. The thinnest zone on the work piece shifted
from the bottom to the opening of the spun cup, while the spinning process progressed. [Lin
2015] proposed three different patterns of deformation allocation for curvilinear generatrix
parts, including equal max deformation (EMD), equal arc length (EAL), and equal axial
distance (EAD). They developed a 3D elastic-plastic finite element model to investigate the
effects of deformation allocation on forming quality. This paper focused on studying the
effect of blank thickness on the SSMF process in term stress distribution, thickness variation
and wrinkling suppression.

2- STRESSES IN THE CONVENTIONAL SPINNING PROCESS :

Through the conventional spinning process, a local plastic deformation zone is created at the
roller contact area. The stress forms in this zone depends on the roller feeding direction. In the
forward pass (the roller feeds in the direction of the edge of the blank of sheet metal), tensile
radial stresses and compressive tangential stresses are induced, as shown in Fig.2a. The
tensile radial stresses lead to a material movement to the edge of the blank producing thinning
of the blank, which is balanced by the thickening effects of the compressive tangential
stresses, keeping a nearly constant thickness. In the backward pass (the roller feeds in the
direction of the mandrel), though, the material builds up in front of the roller, producing
compressive radial stresses and compressive tangential stresses, as shown in Fig.2b [Runge
1994].

3- STRESSES DISTRIBUTION :

The spinning procedure is very similar to deep drawing process according to the tools at the
press. The process is carried out in one pass from circular plain preparing parts. For full
analyzing of stress state at the spinning it is needed to divide the work piece into several
changed zones. As shown in Fig.3 at which are occurred different schemes of stress. The
stress state is treated as flat at the element wreath, where it is considered that the forming of
material is acted by the absence of normal stress (σ Z ) =0. This stress state is different in
according to radial stress (σ R ) positive and normal stress in the tangent direction is negative
(σ T ). The method of common solution of plasticity conditions is used for an analysis of stress
in the element wreath in the form [Lazarevic 1983]:
𝜎𝑅 − 𝜎𝑇 = ±𝛽𝑘 (1)
Where
𝜎𝑅 = radial stress.
𝜎𝑇 = tangential stress.
β = lode coefficient (1-1.55).
K = number of parameters.

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THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

And the balance equation is [Lazarevic 1983]:

𝑑𝜎
𝜌 𝑅 + 𝜎𝑅 − 𝜎𝑇 = 0 (2)
𝑑𝜌
Where
ρ= radius inside of intervals (r 1 ≤ ρ≤ R o ).
r 1 = radius of the mandrel.
R 0 = radius of blank of sheet metal.
From equations (1) and (2), we get the equation (3)
𝑑𝜎
𝜌 𝑅 + 𝛽𝑘 = 0 (3)
𝑑𝜌
To solve the equation (3), boundary conditions (𝜌 =R S , 𝜎𝑟 =0) are applied, we get radial
stressed component at the element wreath as shown in equation (4).
𝑅𝑆
𝜎𝑅 = 𝛽. 𝑘𝑠𝑟 ln (4)
𝜌
Where
k sr = the average value of specific flow stress.
R S = the immediate value outside wreath radius of the cylinder (from r 1 to R 0 ).
From equation (4) and equation (1), we get
𝑅𝑠
𝜎𝑇 = 𝛽𝑘𝑠𝑟 �ln − 1� (5)
𝜌
The maximum axial stress is defined as [Lazarevic 1983]:
𝑅𝑆 𝑠0
𝜎𝑍𝑚𝑎𝑥 = �1.1𝑘𝑠𝑟 ln + 𝑘𝑠𝑟 � (1 + 1.6𝜇) (6)
𝑟1 2𝜌𝑤 + 𝑠0
Where
s0 = Initial thickness of blank
μ = The coefficient of friction
1
𝑅𝑆 = �(𝐷02 − 4𝑑1𝑠𝑟 [ℎ + 0.57(𝜌𝑤 + 𝑅 + 𝑠0 )])
2
D O = Original diameter of the blank
Where maximum axial stress (𝜎𝑍𝑚𝑎𝑥 ) Obtained by h = 0.

4- FINITE ELEMENT MODELING:

In this paper, a commercial FE code (ANSYS 15) is used to simulate the spinning sheet metal
forming operation. The material of sheet metal is aluminum alloy 1435. The mechanical
properties of this material in experimental aspect are the elastic modulus of elasticity E =
69.500GPa, Poisson's ratio v=0.33, yield strength σ y =130MPa and tangent modulus
E t =0.1GPa. Two Coulomb frictional coefficients have been assigned to two contact pairs of
tools and blank: mandrel-blank 0.2 and roller-blank 0.02 [Razavi 2005]. The parts of the
model in the simulation process are shown in Fig. (4) . The tool set (mandrel and forming
roller) was modeled as rigid bodies. In the present study the elements used to simulate the
blank is SHELL 181, contact elements is CONTA174 and target elements are TARGE170.
The blank diameter is 180mm. Mapped meshing is applied to discretize the plate material.

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Ali S. Gaffer

The best number of elements is (2660) element as it is shown in Fig. (5). SSM forming
processes under the large displacement static condition have been simulated. The load in the
current study is applied by using the solution processor with load step options and then start
the finite element solution. The load is defined by applying of zero all degrees of freedom at
the contact line between the holder and sheet as the first load step, applying of roller travel in
z - direction by distance 120mm and rotating about the z-axis as feed ratio as second load step
and finally rotating about the z-axis by inertia then and finally angler velocity by global as a
third load step.

5-THE EFFECT OF BLANK THICKNESS:

To investigate the effect of blank thickness on SSMF process, three different blank thickness,
i.e. (1,2,3mm) were used. The feed ratio 0.71mm/rev and spindle speed 200rpm. Through the
forming process, failure by cracking is observed with 1mm thickness of the blank, while
failure by wrinkling is observed with 2mm thickness of the blank, while no failure is observed
in the blank with 3mm in thickness. A global cylindrical coordinate system has been used to
demonstrate the output of deformation and stress values. The radial direction is defined in line
with the radial axis of the mandrel, while the tangential direction is in the path perpendicular
to the radial axis and the axial axis of the mandrel. Fig. (6) and Fig. (7) shows the
deformation in z-direction along the wall of the cup for with (2 and 3mm) thickness
respectively. Fig. (8) to Fig. (19) show the nodal solution of the tangential stress, radial stress,
axial stress and Von- Mises stress distribution along the wall of the cup with blank thickness
(1, 2, 3mm). From these figures, it can be seen that the entire material is plastically deformed,
the maximum value of Von-Mises stress on Aluminum cup is 0.321GPa, these values exceed
the yield stresses. The distribution of Von- Mises stress reveals a reasonably uniform level for
the entire of the deformed wall of the cup, but with some variations, especially on the inner
surface of the wall towards the open end. It can be seen that sheet thickness has an important
effect in the deformation process, where the maximum plastic deformation that takes place
near the round corner of the mandrel (cup bottom) results from the maximum axial force.
After that, the force decreases as necking occurs at the corner of the mandrel under large axial
tensile stresses. If the sheet thickness is unable to support these large axial tensile stresses,
circumferential cracking and fracture at the cup bottom are expected. Fig. (20) shows a
typical wall thickness variation in which the part of the base of the cup which was hold
between the mandrel and blank holder is almost constant, while there is local thinning around
the mandrel corner and slight thickening near the open end. Additionally, no wrinkling can be
observed.

5. EXPERIMENTAL WORK :

5.1. Testing the Work Material :

The tensile specimens were machined by a CNC milling machine and then grounded to
the final size using different sand papers with different particle size. Tensile specimen
dimensions shown in Fig. (21) were selected according to the ASTM standard A370 (the ISO
specification). Uniaxial tension tests were carried out using the WDW model (200) with
maximum load capacity 200 KN that is available at Babylon University- Collage of

233
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Engineering Materials as shown in Fig. (22). The specimens were loaded till fracture occurs.
Tensile test was carried out at a crosshead speed (0.5mm/min).
5.2 Manufacturing of the Rig:
Spinning tests were carried out on a general-purpose center lathe after it was temporarily
modified to work as a semi-automatic spinning machine. The values of spindle speed on the
lathe were (31, 40, 50, 63, 80, 100, 125, 160, 200, 250, 315, 400, 500, 600, 800, 1000,
1250,1600 rpm) and feed ratio (0.04, 0.05, 0.063, 0.08, 0.1, 0.125, 0.16, 0.18, 0.23, 0.28,
0.35,0.45, 0.56, 0.71mm/rev) as shown in Fig. (23). The rig for spinning forming process was
composed of the mandrel, blank holder, shaft, base and forming roller. In this work, 180mm
diameter of the blank is selected due to the limitation of space of the available test machine
used in the present work. The mandrel plays a very important role in giving the shape of the
final product. The mandrel used for the experiment is made of steel (St 37) and consist of two
cylindrical parts, the first part attached with a headstock of lath from the left side. The second
part of the mandrel is attached to the other side of the first part by the cylindrical shaft which
has a radius 40mm and length15mm and consist a small hole which has a radius 7.5mm and
depth 20mm to assemble with a blank holder. The blank holder is used to attach the blank
with the mandrel by a small pin from the side and with the tail stock of the lathe from the
other side by a small hole. The forming roller which is the vital part of the forming rig were
designed according to the reference (Xia 2005, Liu 2007, Essa 2009). 0The forming roller
contains two ball bearings (6308NSE) which allow the forming roller to roll freely during the
spinning process. High-strength steel (St-37) was used as a forming roller material The shaft
which is used to carry the forming roller is especially designed to press fit the ball bearing to
give the smooth rotation to forming roller. The base is an important part which is used to
carry the shaft and the forming roller. The base contains five large holes with same diameter
and depth to fix the base on the tool post and to control the location of the roller with respect
to the blank. Also, there is a four small threaded holes used to fix the shaft that carrying the
forming roller by the large hole on side view. The blank contains on the hole in the center
with 15mm diameter for attaching. Fig. (24) shown the mandrel with two parts, plate and
blank holder. Fig. (25) represented the assembled the roller with shaft with the base and
finally Fig. (26)shows assembled rig parts .
6- THE FORMING PROCESS :

The forming process was conducted after loading the blank to the machine and fix it with the
aid of blank holder by moving the tail stock of the lathe. After that the forming was done by
moving the roller (tool post) displacement in the Z-direction (120mm) to create complete
stroke for sheet forming with a predefined feed ratio (0.71mm/rev) and the running speed of
the spindle (200rpm) (according to numerical results). The blank is (180,3 mm) diameter and
thickness aluminum 1435 respectively. The SSMF during the forming process was spanned
by using lathe model (500) with maximum spindle speed (1600 rpm) and a maximum feed
ratio (0.71 mm/rev) in the university of Babylon -mechanical department. In the spinning
sheet metal forming process, the sheet metal will be subjected to changed strains of stretching,
bending and ironing. The new dimensions will result, the product defect are generated such as
wrinkling as can be shown in Fig. (27). Wrinkling is a particular defect in SSMF, which is

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

resulted by compressive tangential stresses in the flange region near the local forming area do
not completely recover to tensile tangential stresses after leaving roller contact. To measure
the product thickness variation along the depth of the cup, the product was divided in two
parts by using reciprocating saw, the cup before and after measuring the thickness as shown in
Fig. (28). Micrometer and electronic digital caliper with an accuracy of (0.01mm) were used
to measure the product thickness variation along the depth of the cup.

Fig. (29) shows the deformation results in the same cup numerically and experimentally. Fig.
(30) shows the comparison between numerical and experimental thickness variation along the
wall of the cup and the comparison results show the error percentage between the numerical
and experimental work is (5.95%) .

7- CONCLUSIONS :

1- In the wrinkle-free product, the compressive tangential stresses recover to tensile tangential
stresses when the current contact area moves away from the roller. Conversely, in the
wrinkling model the compressive tangential stresses induced at the roller contact zone do not
fully recover to tensile tangential stresses after being deformed. This may be because the
compressive stresses at the roller contact zone are beyond the buckling stability limit,
resulting in some compressive tangential stresses remaining in the previous contact zone, thus
leading to the wrinkling failure.
2-It can be seen that sheet thickness has an important effect in the deformation process, where
the maximum plastic deformation that takes place near the round corner of the mandrel (cup
bottom) results from the maximum axial force. After that, the force decreases as necking
occurs at the corner of the mandrel under large axial tensile stresses. If the sheet thickness is
unable to support these large axial tensile stresses, circumferential cracking and fracture at the
cup bottom are expected
3-The best plate thickness to produce a cup of the aluminum plate1435 is 3mm, while the
wrinkling in the cup is observed at 2mm thickness and the fracture in cup in 1mm.
4-Thickness variations obtained by the experimental work are coincide with that obtained by
the numerical method.
5-From the Fig. (30), it can be observed that the necking occurred around the filleted mandrel
edge and thickening towards the part opening.
6- The compared results showed a good agreement between them and the error percentage
did not exceed 5.95% at the part opening.

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THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Fig. (1) Metal Spinning[Runge 1994]

(a) Forward pass (b) backward pass

Fig. (2) Stresses Induced Through Conventional

Spinning[Runge 1994]

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

Fig. (3) Stress and Strain Distribution in

Spinning Process[Lazarevic 1983]

Fig.(4) Final Model in the Simulation

237
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

160
158
156
Von- Mises Stress -Mpa

154
152
150
148
146
144
142
140
950 1450 1950 2450 2950 3450 3950 4450 4950
Elements Number
Fig. (5) Relationship Between Number of Element and Von-Misses Stress

Fig.(6) Deformation in Z- Direction of 2mm Thickness

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

Fig. (7) Deformation in Z- Direction of 3mm Thickness

Fig. (8 )Tangential Stress Distribution Along Wall of Plate (1mm Thickness)

Fig. (9) Radial Stress Distribution along Wall of Plate (1mm Thickness)

239
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Fig. (10) Axial Stress Distribution along Wall of Plate (1mm Thickness)

Fig. (11)Von-Mises Stress Distribution along Wall of Plate (1mm Thickness)

Fig. (12) Tangential Stress Distribution along Wall of Cup (2mm Thickness)

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

Fig. (13 ) Radial Stress Distribution along Wall of Cup (2mm Thickness)

Fig. (14 ) Axial Stress Distribution along Wall of Cup (2mm Thickness)

Fig. (15 ) Von-Mises Stress Distribution along Wall of Cup (2mm Thickness)

241
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Fig. (16) Tangential Stress Distribution along Wall of Cup (3mm Thickness)

Fig. (17) Radial Stress Distribution along Wall of Cup (3mm Thickness)

Fig. (18 ) Axial Stress Distribution along Wall of Cup (3mm Thickness)

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

Fig. (19)Von- Mises Stress Distribution along Wall of Cup (3mm Thickness)

Fig. (20) Thickness Variation along the Wall of Cup (3mm Thickness)

243
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Fig. (21) The Tensile Sample Dimensions

Fig. (22) Tensile Test Machine

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Ali S. Gaffer

Fig (23) General – purpose Center Lathe

First part of mandrel

Sheet

Second part of mandrel Blank holder

Fig.(24) Shown the Mandrel with Two Parts, Sheet and Blank Holder

245
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

Forming Roller

Base

Fig.(25) Represented the Assembled the Roller with Shaft with the Base

Mandrel

Sheet

Roller

Base

Fig. (26) Assembled Die.

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Dr. Abdul Kareem J. The Iraqi Journal For Mechanical And Material Engineering, Vol.16, No3, 2016
Ali S. Gaffer

Fig.(27). Shown the Fig.( 28) Shown the Cup before and after Measuring the
Wrinkling(Thickness 2mm) Thickness(Thickness 3mm)

a b

Fig. (29)Formed Cup:(a) Experimentally and (b) Numerically.

4 Numerical thickness(3mm) Experimental

3.9
3.8
3.7
Thickness variation-mm

3.6
3.5
3.4
3.3
3.2
3.1
3
2.9
2.8
2.7
2.6
2.5
0 10 20 30 40 50
Distance along depth of cup -mm

Fig. (30) Thickness Variation along X-axis

247
THEORETICAL AND EXPERIMENTAL STUDY OF THE EFFECT Dr. Abdul Kareem J.
OF SHEET THICKNESS OF ALUMINUM 1435 ON THE FINAL Ali S. Gaffer
PRODUCT QUALITY AND STRESS DISTRIBUTION IN SPINNING
SHEET METAL FORMING

8- REFERENCE :
Essa K. and Hartley P., " O ptimization of Conventional Spinning Process Parameters by
Means of Numerical Simulation and Statistical Analysis", Proc. I. Mech. E., Vol. 224 Part B:
J. Engineering Manufacture, (2010).

Hamilton S., Long H. , "Analysis of Conventional Spinning Process of a Cylindrical Part

Using Finite Element Methods", Steel research international, Vol. 79 (1), PP. 632-639,
(2010).

Kleiner M., Klimmek C., Gobel R., Homberg W. and Kantz H.," Finite Element Analysis of
Sheet Metal Forming by Spinning", Proc. 7th International Conference on Technology of
Plasticity Yokohama, Japan (2002).

LazarevicD. V. , " Transitional Stress - Strain State and the Force

The Rotary Draw Parts Without Reducing the Thickness
Wall " , XVII Conference on Production Engineering of Yugoslavia,
PP. 19 - 22, (1983).

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Conventional Spinning Under Different Roller -Traces", Journal of Materials Processing
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Variation in Conventional Spinning", The 9th International Conference on Technology of
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Process Using FE Simulation and Experimental Work"., Tehran International Congress on
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Runge M., "Spinning and flow forming", (Pollitt, D. H. Trans), Leifield GmbH, (1994).

Sebastiani G., Brosius A., Homberg W. and Kleiner M., " Process Characterization of Sheet
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Ali S. Gaffer

Wang L. and Long H., "A Study of Effects of Roller Path Profiles on Tool Forces and Part
Wall Thickness Variation in Conventional Metal Spinning", Journal of Materials Processing
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Wang L. and Long H., "Roller Path Design by Tool Compensation in Multi-Pass
Conventional Spinning", Materials and Design, Vol. 32, PP. 2891-2899, (2013).

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