The FEM simulation, in combination with a central statistical experiment design provides a useful tool to invest the deformation behaviour with a low simulation effort. The result is a regression polynomial with three variables. Thereby the linear, quadratic
and interacting influence of each parameter is calculated. It has
been shown, that the workpiece diameter ratio D1 /D2 and the feed rate v have an essential influence to the damage behaviour of ball spinning. One useful result of this investigation is, that the dam- age formula according to Ayada can be reduced by increasing the feed rate and by increasing the ball diameter. Overall, this method allows to predict the necessary process parameters for a damage minimised ball spinning process at the beginning of product devel- opment.