Full active counter-roller spinning for thin-walled cylinders: Macroscopic deformation mechanism, mesoscopic texture evolution, and forming performance strengthening

The reliability and lightweight of hydrogen high-pressure storage present pressing global challenges. The forming mechanism of a novel full active counter-roller spinning (FACRS) process for thin-walled cylinders is studied from the perspective of macro‑meso coupling. This innovative process holds promise as a replacement for conventional mandrel spinning, enabling enhanced integration of form and property in manufacturing hydrogen bottle liners. Employing optimal Latin hypercube sampling, a response surface model is constructed for forming consistency (λ) of inner and outer surfaces, yielding an optimal set of process parameters under the Hooke-Jeeves algorithm. The resulting spun parts exhibit a more balanced and superior performance. A macro‑meso gradual cross-scale coupling simulation methodology is proposed, revealing that the process is characterized by the initial aggregation and subsequent reinforcement of texture, culminating in the formation of a "soft" rotated cubic texture, which still faces impediments or diminishes the orientation of texture. It is demonstrated that the evolution of texture is the result of the interactive coordination of various slip systems. Furthermore, the FACRS experiments and performance tests indicate that while enhancing the axial and circumferential mechanical properties of the spun parts, it also reduces material anisotropy. The grain refinement effect of the process has also led to a more uniform distribution of dimples on the fracture surface. The surface performance of the final spun parts improves by 60.11 %. These enhancements can be attributed to the combined effects of improved forming consistency, coordinated action of slip systems, and grain refinement. These results deepen the understanding of the macro‑meso deformation mechanisms underlying the novel process, providing valuable insights for further advancements in counter-roller spinning technology.