Design improvement of spin forming of magnesium alloy tubes using finite element

Spin formability of magnesium alloy has previously been demonstrated experimentally by the authors. Spin forming using magnesium alloy tubes was demonstrated using an NC control machine at 300°C with a main shaft rotational frequency of 300rpm and feed per revolution of 180 mm/min. A specimen of the magnesium alloy pipe was produced with an outer diameter of 100 mm and a wall thickness of 3 mm by cutting at room temperature. By spin forming, it was possible to form a domed shape similar to a pressure vessel at the end of a pressurised gas cylinder. Simulation of this spin forming process has not been demonstrated to date, due to the difficulty in properly modelling the complex forming mechanisms during the process. This paper discusses the finite element analysis (FEA) simulation of the spin forming of magnesium alloys. This model was constructed based on the material properties at 300°C as recorded in the real forming process.