Dynamic optimization of die-less spinning process through autonomous modeling of time-varying forming law

Die-less spinning is a typical incremental forming technology with flexible processing parameters, including the roller path and loading parameters, whose forming law changes dynamically and easy-to-produce defects of excessive thinning and flange wrinkling. This brings a great challenge to the process design of die-less spinning. In this study, we proposed a novel dynamic optimization approach and system considering the time-varying forming law for the processing parameters in die-less spinning. The idea of proposed approach is that simulating the spinning process step by step through autonomous finite element modeling, real-time extracting and modeling the simulated spinning status at each forming step to capture the time-varying forming law, then gradually optimizing the processing parameters through efficient multi-objective optimization algorithm. By conducting the proposed dynamic optimization approach to the first spinning pass of die-less spinning, series of polynomial response surface models (PRSM) of wall thickness and flange wrinkling at various forming steps were developed to describe the time-varying forming law. On this basis, the roller path and matching loading parameters in each step were gradually optimized through a differential evolution algorithm with the multi-objective of minimizing wall thickness reduction, reducing flange wrinkling and maximizing forming efficiency. The optimized process produced better spun part than the traditional spinning process, presenting the wall thickness reduction ≤5 % and the flange wrinkling ≤2.5 mm. Furthermore, the time-varying influence of processing parameters on the wall thickness and flange wrinkling were elucidated based on the PRSM of spinning status at various forming steps.