An Adaptive Sequential Procedure for Efficient Optimization of the Sheet Metal Spinning Process

2005 ◽  
Vol 21 (5) ◽  
pp. 439-455 ◽  
Author(s):  
Nadine Henkenjohann ◽  
Roland Göbel ◽  
Matthias Kleiner ◽  
Joachim Kunert
Keyword(s):  
Sheet Metal ◽  
Sequential Procedure ◽  
Spinning Process ◽  
Metal Spinning

New Approach for Process Planning and Optimization in Sheet Metal Spinning

2005 ◽  
Vol 6-8 ◽  
pp. 493-500 ◽  
Author(s):  
R. Göbel ◽  
Matthias Kleiner ◽  
N. Henkenjohann
Keyword(s):  
Sheet Metal ◽  
Process Planning ◽  
Statistical Design ◽  
Case Based Reasoning ◽  
Systematic Design ◽  
Statistical Design Of Experiments ◽  
New Approach ◽  
Design And Optimization ◽  
Spinning Process ◽  
Metal Spinning

Due to the high complexity and the large number of possible geometries to be formed, a systematic design of the sheet metal spinning process is, up to now, difficult and time consuming. Sustainable models of the spinning process do not exist so far. Due to this, a new approach for the systematic design and optimization of the spinning process has been developed. In a first step of the planning sequence, a prediction of initial parameter settings is given by a case-based-reasoning approach. A first adaptation of the pre-selected parameters is then realized on a fuzzy-based model. In the next step, a model based optimization using statistical design of experiments is performed. For this, a new statistical approach has been developed being optimized regarding the requirements of the spinning process. In this paper, the methods used and the implementation of the approach in a process planning software are described. The approach is verified by the example of setting up a process to manufacture a cylindrical model workpiece.

scholarly journals Experimental Investigation on the Geometrical Accuracy of the CNC Multi-Pass Sheet Metal Spinning Process

2018 ◽  
Vol 2 (3) ◽  
pp. 59 ◽  
Author(s):  
Mohamed Abd-Alrazzaq ◽  
Mahmoud Ahmed ◽  
Mohamed Younes
Keyword(s):  
Sheet Metal ◽  
Feed Ratio ◽  
Shape Accuracy ◽  
Factors Affecting ◽  
Geometrical Accuracy ◽  
Computer Numerically Controlled ◽  
Spinning Process ◽  
High Feed ◽  
Metal Spinning ◽  
Localized Plastic Deformation

The geometrical accuracy of multi-pass sheet metal spinning products is crucial in many applications. Aerospace, petroleum, and chemical industries motivated the development of modern spun components of complicated shapes with special functionality, but a substantial research lag exists behind this progress. Due to the localized plastic deformation involved, careful control of dimensions and form is required in spinning procedures. In this study, two sets of experiments were implemented for cup manufacturing using a retrofitted computer numerically controlled (CNC) spinning machine to identify the critical factors affecting product geometry and reveal their influence on the shape accuracy of the spun cups. The first set is a screening experiment to determine the most significant parameters and the second provides the optimum processing conditions affecting cup quality. The feed ratio, number of spin-forming passes, spinning ratio, and lubrication were found to have the most important effect on the geometry of the spun cups. Optimum quality with a higher processing speed (productivity) was achieved under a lubricated condition using a larger number of spin-forming passes at a high feed ratio, diminishing the commonly adopted rule of slow spinning for accurate products and reflecting a significance for state-of-the-art spinning practice. The findings of this paper introduce a basis for a spinning quality database.

Process Characterization of Sheet Metal Spinning by Means of Finite Elements

2007 ◽  
pp. 637-644
Author(s):  
Gerd Sebastiani ◽  
Alexander Brosius ◽  
Werner Homberg ◽  
Matthias Kleiner
Keyword(s):  
Finite Elements ◽  
Sheet Metal ◽  
Process Characterization ◽  
Metal Spinning

Process Characterization of Sheet Metal Spinning by Means of Finite Elements

2007 ◽  
Vol 344 ◽  
pp. 637-644 ◽  
Author(s):  
Gerd Sebastiani ◽  
Alexander Brosius ◽  
Werner Homberg ◽  
Matthias Kleiner
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Flexible Manufacturing ◽  
Theoretical Models ◽  
Element Model ◽  
Axially Symmetric ◽  
Element Analysis ◽  
Cross Sectional ◽  
Process Characterization ◽  
Metal Spinning

Sheet Metal Spinning is a flexible manufacturing process for axially-symmetric hollow components. While the process itself is already known for centuries, process planning is still based on undocumented expertise, thus requiring specialized craftsmen for new process layouts. Current process descriptions indicate a vast scope of different dynamic influences while the underlying mechanical model uses a simple static approach. Thus, a 3D Finite Element Model of the process has been set up at IUL in order to analyze the process in detail, providing online as well as cross sectional data of the specimen formed. Within the scope of this article, the results of the above mentioned Finite Element Analysis (FEA) are presented and discussed with respect to the qualitative stress distributions introduced in the existing theoretical models. Main emphasis of this paper is set on a discussion of the qualitative stress distribution, which is, to the current state, only known in theory.

Combined Methods for the Prediction of Dynamic Instabilities in Sheet Metal Spinning

CIRP Annals ◽  
2002 ◽  
Vol 51 (1) ◽  
pp. 209-214 ◽  
Author(s):  
M. Kleiner ◽  
R. Göbel ◽  
H. Kantz ◽  
Ch. Klimmek ◽  
W. Homberg
Keyword(s):  
Sheet Metal ◽  
Metal Spinning ◽  
Combined Methods

Hybrid Rapid Spinning and Incremental Sheet Metal Forming of Extra Deep Drawing (EDD) Steel

2016 ◽  
Author(s):  
Srinivasa Prakash Regalla ◽  
Kurra Suresh
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Canola Oil ◽  
Hybrid Process ◽  
Molybdenum Disulphide ◽  
Second Stage ◽  
Spinning Process ◽  
Incremental Sheet Metal Forming ◽  
Two Stages ◽  
Manufacturing Time

In this work, investigation into a two-stage hybrid and integrated incremental sheet metal processing of EDD sheet has been carried out. EDD steel was chosen for its excellent formability. The hybrid process consists of two stages, the first stage is the conventional spinning process and the second stage is the asymmetric incremental sheet metal forming (AISF) process. The objectives of the proposed hybrid process are reduction of manufacturing time and improved surface finish, in comparison to AISF process alone. In the proposed hybrid process, the geometry of sheet metal part was sub-divided into two groups of features. The first group of axisymmetric features was obtained by spinning process, on top of which, in the second stage, the second group of asymmetric features was superimposed by AISF process. The hybrid process for studying the manufacturing time consisted of negative AISF in the second stage. A substantial overall reduction in manufacturing time was observed. The hybrid process for studying improved surface finish consisted of, on the other hand, positive AISF in the second stage, in which the experiments were carried out using four different lubricants, namely plain canola oil and three different additives in canola oil, namely, molybdenum disulphide, boric acid and maleic anhydride. The surface topography of the sheet in the two stages of hybrid process was determined using a profilometer. It is found that canola oil with molybdenum disulphide gives the best surface quality.

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