Analysis of shear spinning process

Shear spinning process is used for manufacturing hollow, rotationally symmetric parts used in the aerospace, nuclear, defense, and automotive industries. The process has been invented about 60 years ago and used widely in the industry. However, the literature and the understanding of process mechanics are limited. This thesis investigates the process mechanics through numerical models and a series of physical trials using commercially pure copper. Shear spinning process is modeled using Abaqus FE 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. The validated model is then employed for investigating the process mechanics and the underlying mechanism of deformation under various process conditions. Lastly, an attempt is made to define a process operating window.