Spun-part wall thickness is a key output parameter of spinning products. Thickness affects the spun part strength: Low thickness leads to cracks on spinning products. Hence, it is crucial to measure and control wall thickness. However, thickness measurement and a control system for the spinning process are still offline methods. That is, these parameters must be measured after the spinning process is completed. In this method, the cross section of the spun part is cut, and the wall thickness is measured using a measurement tool. Thus, the measurement system is not applicable as online method. Hence, this study proposed the online thickness measurement method for the spun. Here, the mandrel-less spinning machine and a line laser measurement system were developed. The line laser measurement system, including two sets of line lasers and cameras, was attached on the spinning machine. Both sets of line lasers and cameras were used to measure the thickness profile of the spun part. The first set of a line laser and camera was used to capture the surface profile in the front of the spun part, while the other set was used to capture the surface profile behind the part. Then, the digital image processing (DIP) was estimated the spun thickness by using both images. In the experiments, the spun part was formed by the variation of degrees of angle and spinning distance. In each experiment, the spun-part thickness was measured by the cross-section method and line laser measurement method. Both results were compared and discussed. The result revealed that the thickness estimated by the line laser measurement system is similar to that estimated by the cross-section measurement method. An average error of 3.67% was obtained by the line laser measurement system.
Metal spinning process is widely used for producing complex symmetry components. Main advantage of spinning process is a lower power requirement for large deformation with good surface finish. The aim of this paper is to investigate the influences of spinning process parameters, on spinning force. A three dimensional finite element model of the spinning process of SPCC sheet was successfully developed using elastic-plastic material property. The spinning experiments were carried out on a turning lathe and spinning forces were measure forces using a piezoelectric force transducer. The finite element prediction was compared with the experimental measurements and the results agreed well. Applying the Taguchi method, the effect of four process parameters, i.e. roller diameter, spindle speed, feed rate and feed depth, on spinning force were studied. The Taguchi main effect analysis and ANOVA results show that roller diameter and feed depth are the most important factor influencing the spinning force.
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