Analysis and modelling of a rotary forming process for cast aluminum alloy A356

TL;DR

This paper investigates the spinning process of aluminum alloy A356 using experimental methods and a coupled thermomechanical finite element model to predict geometry and understand process-induced defects.

Contribution

It introduces a novel large-scale experimental setup and a detailed finite element model for A356 spinning, addressing size, shape, and material representation.

Findings

Model predictions align with experiments for small deformations

Errors increase with larger deformations

Characterization of mechanical states leading to defects

Abstract

Spinning of a common aluminum automotive casting alloy A356 (Al-7Si-0.3 Mg) at elevated temperatures has been investigated experimentally with a novel industrial-scale apparatus. This has permitted the implementation of a fully coupled thermomechanical finite element model aimed at quantifying the processing history (stress, strain, strain-rate and temperature) and predicting the final geometry. The geometric predictions of this model have been compared directly to the geometry of the workpieces obtained experimentally. This study is novel in regards to both the size and shape of the component as well as the constitutive material representation employed. The model predictions are in reasonable agreement with experimental results for small deformations, but errors increase for large deformation conditions. The model has also enabled the characterization of the mechanical state which leads to a common spinning defect. Suggestions for improving the accuracy and robustness of the model to provide a predictive tool for industry are discussed.