Aluminum Wheel Spinning Simulation
A DEFORM-3D simulation modeled the spinning process that is used to form the rim on an aluminum automotive wheel.
Product: DEFORM Premier; DEFORM-3D
Summary:
Aluminum wheel manufacturing processes often involve spinning of the rim shape following bulk forging or casting. The spinning or flowforming equipment used in these processes typically includes one to three rollers. The rollers progressively form the material against a shaped mandrel using one or more spin passes. This approach efficiently and cost-effectively produces a net or near-net shaped rim profile.
The DEFORM system has been used to simulate wheel forging processes for decades. Spinning processes, on the other hand, had traditionally been prohibitive to analyze with finite-element analysis. The challenge was due to the extreme computational cost required to model the large number of rotations, multiple object translations and long process duration involved.
Recent developments in simulation technology has now opened the door to spinning process analysis. Cases similar to the aluminum wheel shown here may now be practical to simulate using the advanced finite-element capabilities available in DEFORM-3D.
Reference:
Cha, Wg., Hwang, S.Y., Kim, N. et al. Analysis of mechanism of backflow defect of the aluminum wheel flow forming. Int. J. Precis. Eng. Manuf. 15, 1075–1080 (2014).
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