Numerical Simulation and Development of Tube Spinning Process for Exhaust System Components of Motor Vehicles

A numerical analysis method by FE for the tube spinning process for exhaust system components was developed. This method makes it possible to analyze the evolution of shape, thickness, and other geometrical factors, strain, and stress distribution in the material, giving a clear understanding of the mechanism of failures such as cracking and buckling during spinning. A particular case is presented, in which prior process design using this FE analysis technique significantly shortened the development period with a combined forming technology including spinning and other processes.