Laser-assisted metal spinning for an efficient and flexible processing of challenging materials

Abstract

Abstract. The demand for components made from high performance materials like titanium or nickel-based alloys as well as strain-hardening stainless steel is steadily increasing. However, conventional forming operations conducted on these materials are generally very laborious and time-consuming. This is where the limitations of metal spinning also become apparent. Using a laser to apply heat localized to the forming zone during metal spinning facilitates to enhance the formability of a material. In order to analyse the potential of the new manufacturing process, experimental investigations on laser-assisted shear forming and multi-pass metal spinning have been performed with austenitic stainless steel X5CrNi18-10, nickel-based alloy Inconel 718 and titanium grade 2. It could be demonstrated that the formability of these materials can be enhanced by laser-assistance. Besides the resulting enhancement of forming limits for metal spinning of challenging materials, the forming forces were reduced and the product quality was improved significantly.

A Manufacturing Driven Design Methodology to Lightweighting of the Structural Elements of a Permanent Magnet Electrical Machine Rotor

“…Before deciding on the material and manufacturing route, it is important to note that there will be limitations on the conditions in which the material can be processed using a certain route. For example, titanium is formable using the spinning process, but due to the microstructure of this material, the spinning process needs to be conducted at high temperature, typically in the region of 600−800 °C [29], with research being conducted into the use of laser-assisted spinning for difficult to deform, high strength alloys [30].…”

study on laser-assisted spinning of aged Aluminum alloy sheet

“…Hino [6] revealed that the forming limit of AZ31 magnesium alloy increases with the laser power increases in laser-assisted incremental forming. Brummer [7] carried out the laser-assisted spinning of titanium alloy, and results show that the laser-assisted spinning could avoid cracking, improve geometric accuracy. Up to now, most of the researches focus on the improvement of forming limit of annealed material and geometric accuracy of thin-walled components by laser-assisted spinning.…”

Study on Wall Heights and Surface Roughness of Spun Cups Produced of Metal Blanks by Multipass CNC Spinning Technology

“…Different shapes, such as cylindrical, conical, or spherical, can be formed using suitable mandrel geometries and roller traces [2,5,6]. Conventional metal spinning is typically performed at room temperature; however, elevated temperature metal spinning is performed for components with thick sections or for alloys with low ductility [7,8]. Conventional spinning is only economically effective for low volume production (less than 1000 pieces).…”