There is a considerable difference in wall thickness between the mouth and the cavity of thin-walled and thick-mouthed seamless gas cylinders, and the existing manufacturing processes are unable to effectively meet product requirements. To overcome such issue, a step-by-step boring-necking-spinning solution for gas cylinders was proposed, in which sufficient wall thickness is reserved for the mouth area of the cylinder blank, followed by necking-spinning to realize the overall forming of thin-walled, thick-mouthed seamless gas cylinders. The stress-strain distribution and geometric dimensional changes of gas cylinders during the spinning process were investigated by means of finite element simulation, and the effects of different process parameters on the stress and wall thickness of the bottle mouth were analyzed. Further, multi-objective optimization of the response surface model was performed using the NSGA-II algorithm to derive a set of optimal process parameters. Finally, the correctness of the simulation and optimization results was verified experimentally, and the expected geometry and optimal strain state of the gas cylinder were obtained. The newly developed processing solution represents a groundbreaking advancement in the manufacturing of thin-walled and thick-mouthed gas cylinders.
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