Influence of Inner Roller Geometric Parameters on Counter-Roller Spinning with 6061 Aluminum Alloy Tube

The inner roller exerts a supportive and thinning effect on the inner side of the tube during counter-roller spinning. In this paper, the Finite Element Analysis (FEA) model of counter-roller spinning for a 6061 aluminum alloy tube was established based on the ABAQUS/Explicit module. The deformation characteristics and the influence of inner roller geometrical parameters on the tube spinning were analyzed. The results showed that the stress–strain on the outer of the tube was greater than that of the inner, and flaring was more prone to occur in the initial stage of counter-roller spinning compared to traditional mandrel spinning. The order of the effects of geometrical parameters of the inner roller on the roundness error and wall thickness deviation was as follows: nose radius > diameter > front angle. The order of factors influencing the inner and outer spinning force was as follows: diameter > nose radius > front angle. Increasing the diameter of the inner roller can improve the spinning stability and forming accuracy of counter-roller spinning. It was beneficial to improve the forming accuracy when the nose radius of the inner roller was slightly larger than that of the outer roller. The front angle of the inner roller has little influence on the spinning forming accuracy.