Wrinkle suppression in metal spinning using Flanged-Edge blanks: experiments and finite element analysis

Wrinkle formation is a common defect in metal spinning, particularly during conventional spinning processes. This study investigates the use of a flanged-edge blank to prevent wrinkles by increasing the blank’s edge rigidity. The process forms an angled flange along the blank’s periphery with a spinning roller before performing the first pass of conventional spinning. Finite Element simulations were conducted to evaluate how flange geometry (angle and length) influences wrinkle initiation, and corresponding experiments compared flanged-edge blanks to flat blanks. Analytical calculations of the blank’s second moment of inertia indicate that adding a flange significantly increases bending stiffness. Larger flange angles and longer flanges redistribute material farther from the neutral axis, thereby elevating bending rigidity and raising the critical compressive stress threshold for buckling, which is consistent with classical plate buckling theory. Simulations and experiments confirmed that flanged-edge blanks with a 30° flange angle remained wrinkle-free, whereas flat blanks under identical conditions suffered severe wrinkling. The flange angle emerged as a key parameter in achieving the necessary rigidity and structural stability to suppress wrinkles. Overall, the results confirm that the spinning flanging technique is an effective method to improve conventional metal spinning processes, with significant potential for broader industrial applications.