Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube

Ren, Xuesong; Fan, Zuojun; Jia, Zhen; Shen, Yongping; You, Huanzhang

doi:10.3390/ma18163858

Open AccessArticle

Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube

by

Xuesong Ren

¹

,

Zuojun Fan

²,

Zhen Jia

^1,*

,

Yongping Shen

^1,* and

Huanzhang You

¹

School of Aerospace Engineering, Shenyang Aerospace University, Shenyang 110136, China

²

Prosper Metal Forming Corporation, Xi’an 710089, China

^*

Authors to whom correspondence should be addressed.

Materials 2025, 18(16), 3858; https://doi.org/10.3390/ma18163858

Submission received: 8 July 2025 / Revised: 3 August 2025 / Accepted: 11 August 2025 / Published: 18 August 2025

(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control, and Performance Optimization)

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Abstract

To address the challenges of non-axisymmetric tube spinning, this study employs finite element simulations to validate a novel spinning method for right-angle groove tubes. Three forming schemes with distinct roller path geometries were designed and analyzed using Simufact Forming, with 6063-O aluminum alloy tubes serving as the research material. The simulation results indicate that multi-pass forming (Schemes I and II) significantly enhances wall thickness uniformity compared to single-pass forming (Scheme III). Scheme I exhibits optimal performance due to the minimized equivalent stress in the final forming pass. The maximum stress is concentrated at the groove bottom, leading to wall thinning and springback, while the maximum strain occurs at the roller exit point, where metal accumulation causes local wall thickening. Experimental observations confirm the consistency with the simulation results, validating the model’s reliability. This study deepens the understanding of deformation mechanisms in complex groove forming, highlighting the roller path geometry in controlling stress-strain distribution and final product quality.

Keywords: non-axisymmetric die-less spinning; right-angle groove; finite element simulation

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MDPI and ACS Style

Ren, X.; Fan, Z.; Jia, Z.; Shen, Y.; You, H. Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube. Materials 2025, 18, 3858. https://doi.org/10.3390/ma18163858

AMA Style

Ren X, Fan Z, Jia Z, Shen Y, You H. Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube. Materials. 2025; 18(16):3858. https://doi.org/10.3390/ma18163858

Chicago/Turabian Style

Ren, Xuesong, Zuojun Fan, Zhen Jia, Yongping Shen, and Huanzhang You. 2025. "Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube" Materials 18, no. 16: 3858. https://doi.org/10.3390/ma18163858

APA Style

Ren, X., Fan, Z., Jia, Z., Shen, Y., & You, H. (2025). Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube. Materials, 18(16), 3858. https://doi.org/10.3390/ma18163858

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

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Numerical Simulation Study on Non-Axisymmetric Die-Less Spinning with a Right-Angle Groove in the Tube

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