Development of a Novel Tool for Sheet Metal Spinning Operation

Abstract

Metal spinning is one of the metal forming processes that allow production of hollow, axially symmetric sheet metal components. The basic technique of spinning, consists of clamping a sheet metal blank against a mandrel on a spinning lathe, and roller gradually forces the blank onto the mandrel. Conventional spinning process requires multiple passes for the complete deformation of sheet metal blank, in order to maintain wall thinning ratio. The spinning process design still highly relies on experienced spinners using trial-and-error. Challenges remain to achieve high product dimensional accuracy and prevent material failures. This M. Tech project aims to develop a novel tool for metal spinning operation by considering material deformation and failure mechanics like wrinkling and circumferential cracking in the conventional spinning process by employing experimental method. This project also aims to convert this skilled work of metal spinning into technique on conventional lathe machine. By using this technique, the time and materials wasted by using the trial-and-error can be decreased significantly. In addition, it may provide a practical approach of standardized operation for the spinning industry and thus improve the product quality, process repeatability and production efficiency.

Formability of the material has been studied to form a cylindrical cup with spinning using conventional tool and spring loaded tool. It has been found that more cup depth can be produced with spring loaded tool. This will help to device spinning technique independent of skilled spinner.