Design of Adjustable Mandrel and Optimization of Spinning Forming Process for Thin-walled Conical Parts

ZHANG Yu; WANG Shuo; WANG Cheng; ZOU Jie

doi:10.3969/j.issn.1674-6457.2026.07.023

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 249-258. DOI: 10.3969/j.issn.1674-6457.2026.07.023

Advanced Manufacturing Technology and Equipment

Design of Adjustable Mandrel and Optimization of Spinning Forming Process for Thin-walled Conical Parts

ZHANG Yu^*, WANG Shuo, WANG Cheng, ZOU Jie

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Abstract

The work aims to propose an adjustable mandrel spinning forming method to meet the "multi-variety and small-batch" production demand of thin-walled conical parts. A flexible mandrel composed of a central mandrel and circumferential adjustable ring units was designed based on the discrete combination concept. With the adjustable unit fillet radius, unit wall thickness, roller gap ratio, roller fillet radius and roller mounting angle as experimental factors, an orthogonal experiment was constructed to investigate the effects of structural parameters on wall thickness difference, straightness, average wall thickness deviation, and minimum thinning rate. A Kriging surrogate model was established, and multi-objective optimization was performed with the AMGA-HJ algorithm. Finite element simulations were conducted to compare the forming laws of conventional mandrel spinning, dieless spinning, and adjustable mandrel spinning and verify the forming advantages of adjustable mandrel spinning. The adjustable mandrel spinning enabled stable forming of various thin-walled conical parts, combining the supporting performance of conventional spinning and the flexibility of dieless spinning. Multi-objective optimization was adopted to obtain the optimal solution of structural parameters. The average wall thickness deviation rate of formed parts was reduced to 2.823%, the wall thickness difference and generatrix straightness were greatly improved, and the simulation prediction error was less than 5%. The designed adjustable mandrel features a reasonable and feasible structure, which effectively improves the flexibility of the spinning process and provides a novel flexible manufacturing technical scheme for forming thin-walled rotary parts of multiple specifications.

Key words

adjustable mandrel spinning / wall thickness uniformity / thin-walled conical parts / orthogonal design / multi-objective optimization

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ZHANG Yu, WANG Shuo, WANG Cheng, ZOU Jie. Design of Adjustable Mandrel and Optimization of Spinning Forming Process for Thin-walled Conical Parts[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 249-258 https://doi.org/10.3969/j.issn.1674-6457.2026.07.023

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