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

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.