The influence of part asymmetry on the achievable forming height in multi-pass spinning

Russo, Iacopo M.; Cleaver, Christopher J.; Allwood, Julian M.; Loukaides, Evripides G.

doi:10.1016/j.jmatprotec.2019.116350

Cited by 13 publications

(7 citation statements)

References 21 publications

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“… Table VIII elucidated that the number of points lie outside tolerance was 87 point from 101 point which consider a high error value or part was fail when 16 mm diameter of tool ball was used, as shown in figure (3) for the same sample 8.  The minimum error in average dimension was 1.705 as shown in Table II for sample 2 which formed under spindle speed 48 RPM, feed ratio 0.22 mm/rev, and tool ball diameter 22 mm, due to the low spindle speed, which coincide with the result by Jacopo M. Russo et al (2020) [4] .…”

Section: Resultssupporting

confidence: 79%

“…Figure (4) shows the schematic illustration of the main effect of parameters on the average error. Also, Tables (X) shows the percentage effect of each parameter on the dimensional error, of the rectangular spun part…”

Section: Analysis Of Variancementioning

confidence: 99%

“…In the cone forming the wrinkling occurred when the angle increases largely. On the other hand, the rectangular polygon was formed using rotational pass sets, folds appeared identical to the folds in conical types [2], furthermore Jacopo M. Russo et al (2020) [4], presented an investigation for manufacturing a non-conventional spun part using an adaptive new conceptual design machine, were attempted to produce a square and the form of a bean cross-section cup. Where In the beginning, a suitable design of blanks was achieved for such geometry, and showed that possible to eliminate the mandrel, and thus decreases costs, lead times, and materials substantially.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Experimental Investigation of Dimensional Accuracy in Non-traditional Sheet Metal Spinning Process for Producing Rectangular Spun Part

Saleh¹,

Aseel²,

Bedan³

2021

ETJ

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The non-conventional spinning process for producing polygons cross-section.  Dimensional accuracy to check methodology of producing rectangular cross-section.  The measure opposite took place by offsetting the design points along normal vector.  The NC milling machine was used to obtain the Data (x, y, and z coordinate).  Forming ball diameter mainly increases the dimensional accuracy average error.The non-conventional spinning process was adopted for producing polygons, but one of the process limitations is the error between design and the final product especially with no-mandrel. Dimensional accuracy was adopted for this purpose which gives an indicator of the ability of the formed part to matches the design and checking validated of the adopted methodology for producing rectangular cross-section spun parts, by comparing the coordinating points of real part with the points of the design model. The point of a real part was measured by using a sphere probe fixed on the three-axis milling machine and capturing the data of machine axis movements for the center location of the probe, also, the measurements oppositely took place, by offsetting the points of design along the normal vector for comparison with the real part points. Three parameters were invested for study the effects on the dimensional accuracy, these parameters are spindle speed (48, 68, and 135 RPM), feed ratio (0.16, 0.22, and 0.32 mm/rev), and the ball diameter of the forming tool (16, 22 and 25 mm). The results show that tool ball diameter mainly affecting dimensional accuracy with a higher value of average error reach (6.47mm) when 16mm diameter of tool ball was used, on the other hand, the minimum average error was 1.705mm at low spindle speed.

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Section: Resultssupporting

confidence: 79%

Section: Analysis Of Variancementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Experimental Investigation of Dimensional Accuracy in Non-traditional Sheet Metal Spinning Process for Producing Rectangular Spun Part

Saleh¹,

Aseel²,

Bedan³

2021

ETJ

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show abstract

“…They reported higher spinning ratio for axisymmetric components than asymmetric forms. Russo et al (2020) investigated the formation of asymmetric parts of 1050-H14 aluminum alloy in a multi-pass mandrel-free spinning process by controlling the trajectory of two rollers, namely the blending and working rollers. Their study aimed to develop an algorithm of tool path generation that could be applied to all target geometries, while avoiding tearing and minimizing thinning and shape errors of the spun samples.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and experimental investigation: Metal spinning process of stepped thin-walled cylindrical workpiece

Seyedzavvar

Oliaei

et al. 2022

Turkish Journal of Engineering

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Sheet metal Spinning process Feed rate Mandrel rotational speed Stress and strain Wrinkling. Many equipment and devices utilized in the aerospace industry are formed as symmetric parts through high plastic deformation of high strength sheet metal alloys with low thickness. Considering the inherent advantages of the spinning process of simple tooling and concentrated deformation loading, this process can be considered as one of the main options in producing these thin-sectioned lightweight parts. In this study, a Finite Element (FE) model has been developed to simulate the formation of a stepped thin-walled cylindrical workpiece of AISI 316 stainless steel alloy by spinning process. The FE simulation results were employed to investigate the effects of process parameters, including feed rate of the roller and rotational velocity of the mandrel on the distribution of stress and strain in the sheet metal, wrinkling failure, and thinning of the sheet metal during deformation. Experiments were carried out using selective input parameters based on the results of FE simulations. The comparison between FE simulations and experiments revealed that the developed model could predict the thinning of the sheet metals with over 93 % accuracy. Additionally, a good agreement between the experimentally deformed sheet configurations with those resulting from finite element simulations has been observed.

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“…However, the roller path was not accurate enough without considering the roller's diameter. Russo et al [13] investigated the influence of part asymmetry on the achievable forming height in multi-pass spinning. The roller path is generated by a algorithm in the CAD software.…”

Section: Introductionmentioning

confidence: 99%

Modification of roller path for square cone by die-less asymmetric spinning

Han

Xiao

Zhou

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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In our previous studies, numerical simulations and experiments were carried out to understand the mechanism of asymmetric spinning for square cone shape. However, the geometry of the products does not coincide well with the geometry in theory. Therefore, in this study, the relationship between the roller and the product is analyzed and a modified roller path is deduced through geometric approach. The result shows the geometry has improved a lot. The relative error of the wall straightness λ drops from 15.9 to 4.1% after modifying. The modified roller path does not have much effect on the wall angle and the wall thickness.

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The influence of part asymmetry on the achievable forming height in multi-pass spinning

Cited by 13 publications

References 21 publications

Experimental Investigation of Dimensional Accuracy in Non-traditional Sheet Metal Spinning Process for Producing Rectangular Spun Part

Experimental Investigation of Dimensional Accuracy in Non-traditional Sheet Metal Spinning Process for Producing Rectangular Spun Part

Numerical simulation and experimental investigation: Metal spinning process of stepped thin-walled cylindrical workpiece

Modification of roller path for square cone by die-less asymmetric spinning

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