Experimental study of asymmetric multi-pass spinning
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ORIGINAL ARTICLE
Experimental study of asymmetric multi-pass spinning Yong Xiao 1,2 & Zhiren Han 1,2
&
Shuyang Zhou 1,2 & Zhen Jia 2
Received: 11 August 2019 / Accepted: 9 August 2020 / Published online: 15 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Various approaches to produce non-axisymmetric parts in metal spinning have been developed by researchers. In asymmetric multi-pass spinning, the motion of the roller is synchronized with the mandrel’s rotation by CNC codes to achieve oblique or noncircular shapes. In this study, cylindrical cups are formed using two kinds of oblique pass sets to investigate the effects of different parameters on thickness distribution and forming limit. In the translational pass set, the inclination angle is determined by the difference of the wall depths on two sides of the product and it is determined by the difference of half cone angles in the rotational pass set. The difference of wall thickness distribution in the translational pass is greater than that in the rotational pass and it increases as the inclination angle increases. The difference between the axial distributions on two sides of the wall decreases as the pass pitch increases near the top of the product, and it increases near the edge of the wall. A greater incremental angle does not affect the difference but reduces the uniformity of the wall thickness in the rotational pass set. All the failures are wrinkles in the experiments. Wrinkles occur when the pass pitch or the roller feed ratio is too large. A greater inclination angle reduces the forming limit in the translational pass set and does not affect the forming limit in the rotational pass set. Keywords Metal spinning . Asymmetric spinning . Multi-pass spinning . Thickness distribution . Tool path
1 Introduction Metal spinning is one of the metal forming processes which transform flat sheet metal blanks into axisymmetric hollow shapes. It is widely used for producing round metal parts for the aerospace and automotive industries, musical instruments, and kitchenware. It has a number of advantages when compared with other forming techniques such as deep drawing or press forming. The products usually have high-quality surface and mechanical strength. It requires low forming forces for the high-strength material and has a low tooling cost. Simple and non-dedicated tooling provides flexibility and shapes with complex geometries. In recent years, advanced methods, which enable the non-circular shapes, are developed to overcome the
* Zhiren Han [email protected] 1
School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, Shaanxi, China
2
Key Lab of Fundamental Science for National Defense of Aeronautical Digital Manufacturing Process, Shenyang Aerospace University, Shenyang 110136, China
limitation of traditional spinning. Amano and Tamura [1] successfully formed an elliptical shape by synchronizing the roller’s motion with the rotation of the spindle by using a mechanical cam. This method shows w
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