Quality prediction of plunger components based on the finite element method during the neck-spinning process

To improve the neck-spinning processing quality of plunger components, a reliable finite element (FE) model was established and validated by the experimental spinning force. In the advanced FE model, an additional analysis step was added to obtain the pulling-out force, the axial clearance, and the swing angle of the plunger components after the neck-spinning process. Thus, the neck-spinning quality of the plunger components can be predicted. The results show that the simulated results using the FE model agree with the experimental results very well. The radial and axial spinning forces are approximate 3 and 2 times of the tangential spinning force, respectively. Finally, the influences of spinning parameters (e.g., feed rate and rotating speed) on the finished pulling-out force, axial clearance, and swing angle were evaluated in detail. The pulling-out force increases with increased feed rate, which tends to be stable with increased rotating speed. Compared with the stable tendency of axial clearance affected by feed rates, the axial clearance decreases significantly with increased rotating speeds. The swing angle of plunger components remains stable with different feed rate and rotating speed after the neck-spinning process.