Ball spinning is an incremental forming process for tubes and rods. The deformation of this process is
limited by surface cracking. A closer look pointed out the dependence of some process parameters. The
most influencing parameters are the workpiece diameter ratio D1 /D2 , the tool diameter ratio D1 /d and
the axial feed rate v. A vast number of experiments would be necessary to study all interactions between
these parameters and a 3D FEM simulation would have limitations in the computing time. Hence, this
investigation proposes a 2D FEM model to predict the damage during ball spinning and gives a detailed
view into a statistical design of experiments. The results show a trend to increase the axial feed rate for
a damage minimised process design.