An Investigation Into a Conventional Spinning Process Combined With Flow Forming With Simultaneously Burnishing Processes

Abstract

Spinning process is a sheet metal forming technology used in the production of the symmetrical industrial parts. It is an efficient and inexpensive manufacturing process and has been widely used in various applications. In this research, new technique was developed to perform three different operations in the same stroke, namely conventional spinning, shear spinning (wall thickness reduction) and burnishing processes. This new technique has been performed by a new tool which consists of three stages, the first stage consists of two rollers to carry out conventional spinning process; the second stage includes two opposite balls to perform the process of shear spinning and the last stage comprises another two opposite balls to perform the process of burnishing. The burnishing balls differ from the shear balls in which that the burnishing balls have a spring behind the balls to decide the required burnishing load. Experimental work was conducted and confirmed the success of the presented technique. The response of the product quality and required load to process parameters such as rotational speed (46,76,150 and 230 rpm), axial feed (0.15,0.3,0.6 and 1.21 mm/rev) and burnishing load (20, 25 and 30 KN) was checked and clarified. The results showed that, the optimum condition for forming load occurred at rotation speed at 150 rpm, axial feed 0.3 rev/mm and burnishing load 25 KN.