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

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.

Download Full-text

Study on Spinning Process of a Thin-Walled Aluminum Alloy Vessel Head With Small Ratio of Thickness to Diameter

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4000930 ◽

2010 ◽

Vol 132 (1) ◽

Cited By ~ 11

Author(s):

Yanqiu Zhang ◽

Debin Shan ◽

Wenchen Xu ◽

Yan Lv

Keyword(s):

Aluminum Alloy ◽

Feed Ratio ◽

Small Range ◽

Factors Affecting ◽

Small Ratio ◽

Spinning Process ◽

Conventional Spinning ◽

Thin Walled ◽

Line Trajectory ◽

Blank Size

The thin-walled vessel head with the ratio of thickness to diameter less than 3‰ has long been considered to be difficult to be spun because wrinkling is very likely to occur during the thin-walled vessel head spinning process when the thickness is far smaller than the diameter. Based on process experiments and finite element method, the spinning failure of thin-walled vessel head with a small ratio of thickness to diameter is analyzed in the present research. The mechanism of wrinkling is identified and some effective solutions are discussed to prevent the failure. The results show that the feed ratio, the blank geometry, and the roller trajectory are the main factors influencing the spinning qualities. In the shear spinning, the feasible roller feed ratio is found to be within a very small range because of the thin thickness of blanks. Wrinkling will occur if the feed ratio is slightly outside the operation range. Bending the edge of blank or enlarging the blank size can effectively prevent wrinkling at a larger feed ratio, which would increase the operation range of roller feed ratio. Due to the fact that the conventional spinning is a process of multiple passes, there are many factors affecting the forming quality of thin-walled aluminum alloy vessel head. Wrinkling is likely to happen by the influence of roller trajectory in the first pass due to the fact that the thickness of blank is far smaller than the diameter. The straight-line trajectory is the worst trajectory under which wrinkling is most likely to occur.

Download Full-text

New Approach for Process Planning and Optimization in Sheet Metal Spinning

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.6-8.493 ◽

2005 ◽

Vol 6-8 ◽

pp. 493-500 ◽

Cited By ~ 1

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.

Download Full-text

Adaptive control system to producing a novel spun parts in sheet metal spinning process

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/1105/1/012052 ◽

2021 ◽

Vol 1105 (1) ◽

pp. 012052

Author(s):

Ammar Mahdi Saleh ◽

Assel H Abd ◽

Aqeel S Bedan

Keyword(s):

Adaptive Control ◽

Control System ◽

Sheet Metal ◽

Adaptive Control System ◽

Spinning Process ◽

Metal Spinning

Download Full-text

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

Quality and Reliability Engineering International ◽

10.1002/qre.732 ◽

2005 ◽

Vol 21 (5) ◽

pp. 439-455 ◽

Cited By ~ 14

Author(s):

Nadine Henkenjohann ◽

Roland Göbel ◽

Matthias Kleiner ◽

Joachim Kunert

Keyword(s):

Sheet Metal ◽

Sequential Procedure ◽

Spinning Process ◽

Metal Spinning

Download Full-text

Analysis of Radial Strain Distribution in the Metal Spinning Process by Taguchi Approach

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.472-475.719 ◽

2012 ◽

Vol 472-475 ◽

pp. 719-722

Author(s):

Peter Šugár ◽

Jana Šugárová ◽

Peter Zemko

Keyword(s):

Strain Distribution ◽

Radial Strain ◽

Taguchi Approach ◽

Analysis Method ◽

Anova Analysis ◽

Planar Anisotropy ◽

Factors Affecting ◽

Grid Analysis ◽

Spinning Process ◽

Metal Spinning

The paper presents the results of radial strain distribution measurement throughout the part after multi-pass conventional metal spinning by the circle grid analysis method. The influence of the mandrel speed, workpiece geometry and planar anisotropy of material on the radial strain was studied. For experiment design, an orthogonal array L27 was used and ANOVA (Analysis of Variance) was carried out. Based on the results it is determined that the sequence of factors affecting radial strain corresponds to geometry of spun part, mandrel speed, planar anisotropy of the sheet. In particular, it is found that the workpiece geometry (specific areas of spun part: mandrel/workpiece radius, conical area, cylindrical area) is the most important factor which influences the radial strain of the spun part.

Download Full-text

Friction-Induced Recycling Process for User-Specific Semi-Finished Product Production

Metals ◽

10.3390/met11040663 ◽

2021 ◽

Vol 11 (4) ◽

pp. 663

Author(s):

Thomas Borgert ◽

Werner Homberg

Keyword(s):

High Efficiency ◽

Research Work ◽

Hot Extrusion ◽

Extrusion Process ◽

Efficient Production ◽

Secondary Aluminum ◽

Shape Accuracy ◽

Aluminum Chips ◽

Spinning Process ◽

Complex Parts

Modern forming processes often allow today the efficient production of complex parts. In order to increase the sustainability of forming processes it would be favorable if the forming of workpieces becomes possible using production waste. At the Chair of Forming and Machining Technology of the Paderborn University (LUF) research is presently conducted with the overall goal to produce workpieces directly from secondary aluminum (e.g., powder and chips). Therefore, friction-based forming processes like friction spinning (or cognate processes) are used due to their high efficiency. As a pre-step, the production of semi-finished parts was the subject of accorded research work at the LUF. Therefore, a friction-based hot extrusion process was used for the full recycling or rework of aluminum chips into profiles. Investigations of the recycled semi-finished products show that they are comparable to conventionally produced semi-finished products in terms of dimensional stability and shape accuracy. An analysis of the mechanical properties of hardness and tensile strength shows that a final product with good and homogeneously distributed properties can be produced. Furthermore, significant correlations to the friction spinning process could be found that are useful for the above-mentioned direct part production from secondary aluminum.

Download Full-text

Large-Diameter Line Pipe Expanding Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.192.180 ◽

2012 ◽

Vol 192 ◽

pp. 180-184 ◽

Cited By ~ 1

Author(s):

Ai Xia He ◽

Rong Chang Li

Keyword(s):

Process Parameters ◽

Large Diameter ◽

Dimensional Accuracy ◽

Optimization Method ◽

Main Process ◽

Shape Accuracy ◽

Line Pipe ◽

Factors Affecting ◽

Array Optimization

Mechanical expanding process for large diameter line pipe, a detailed analysis of factors affecting the quality of the final products of the mechanical expansion and proposed optimization using orthogonal array optimization method, as an indicator of dimensional accuracy and shape accuracy of the products, combination of a variety of specifications of mechanical expanding products, the main process parameters to be optimized. Analysis and discussion of results, revealing the degree of influence of various factors on the quality of the final product, and gives the optimum combination of the results. Experiments show that the combination of optimized process parameters, and more help to improve the accuracy of the size and shape of products.

Download Full-text

Research on Ultimate Thinning Rate of Superalloy Spinning

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1035.152 ◽

2021 ◽

Vol 1035 ◽

pp. 152-160

Author(s):

Hai Bao Wu ◽

Fu Long Chen ◽

De Gui Liu ◽

Ji Zhen Li ◽

Jian Fei Wang

Keyword(s):

High Temperature ◽

Process Parameters ◽

Middle Level ◽

Feed Ratio ◽

Forming Limit ◽

Body Parts ◽

Influence Of Process Parameters ◽

Process Guidance ◽

Spinning Process ◽

Thinning Rate

Spinning forming is an effective method for processing thin-walled rotating body parts. The influence of process parameters on the spinning forming limit of materials was studied for the four high-temperature alloys of GH3044, GH3625, GH3536 and GH4169 used in aero-engines. The results can be used as aero-engine high-temperature alloy parts spinning process and provides experimental basis and process guidance. The research results showed that the forming temperature had a significant effect on the spinning forming performance of superalloy materials. When the temperature increased to 800°C and above, the ultimate thinning rate raised 70%. The ultimate thinning rate of GH4169 was higher than the other three materials and GH3044 and GH3536 was at the middle level, GH3625 was relatively low. At the same time, the feed ratio and the corner radius of the rotary wheel had a certain influence on the ultimate thinning rate of different superalloys. The spinning process needs to select reasonable process parameters according to the actual situation when the spinning is applied to manufacture parts.

Download Full-text