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the material is incrementally formed, often there is a net savings in energy in forming over drawing or ironing processes. However, these savings are often not realized because of the inherent difficulties in predicting the resulting deformation for a given roller path. Flow forming subjects the workpiece to a great deal of friction and deformation. These two factors may heat the workpiece to several hundred degrees if proper cooling fluid is not utilized.
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Kegg predicted that for materials with a tensile reduction of 80%, the limiting spinning reduction will be equal or greater than 80%. Kalpakciouglu concluded that for metals with a true fracture strain of 0.5 or greater, there is a maximum limit for the shear forming reduction. For materials with a
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technique in which a disk or tube of metal is formed over a mandrel by one or more rollers using tremendous pressure. The roller deforms the workpiece, forcing it against the mandrel, both axially lengthening and radially thinning it. Since the pressure exerted by the roller is highly localized and
199:. Since it can achieve thin sectioned parts of almost any shape, shear forming is a versatile process used widely in the production of lightweight items. Other advantages of shear spinning include the good mechanical properties of the final item and a very good surface finish.
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The design of the roller must be considered carefully, because it affects the shape of the component, the wall thickness, and dimensional accuracy. The smaller the tool nose radius, the higher the stresses and poorest thickness uniformity achieved.
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In shear forming, the starting workpiece can have circular or rectangular cross sections. On the other hand, the profile shape of the final component can be concave, convex or a combination of these two.
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A shear-forming machine looks very much like a conventional spinning machine, except that it has to be much more robust to withstand the higher forces necessary to perform the shearing operation.
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the area of the final piece is approximately equal to that of the flat sheet metal blank. The wall thickness is maintained by controlling the gap between the roller and the mandrel. In
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1. A sheet metal blank is placed between the mandrel and the chuck of the spinning machine. The mandrel has the interior shape of the desired final component.
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R.L. Kegg, A new test method for determination of spinnability of metals, Transactions of the ASME, Journal of
Engineering for Industry 83 (1961) 119–124.
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C.C. Wong, T.A. Dean and J. Lin, A review of spinning, shear forming and flow forming processes, Int. J. Mach. Tools Manuf. 43 (2003), pp. 1419–1435
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Typical components produced by mechanically powered spinning machines include rocket nose cones, gas turbine engine parts, and dish aerials.
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S. Kalpakcioglu, A study of shear-spinnability of metals, Transactions of the ASME, Journal of
Engineering for Industry 83 (1961) 478–483.
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Flow forming is often used to manufacture automobile wheels and can be used to draw a wheel to net width from a machined blank.
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Shear forming and conventional spinning are being used less than other manufacturing processes such as
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and tearing. Published work on spinnability is available from the authors Kegg and
Kalpakcioglu.
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Highly spinnable materials include ductile materials like aluminum and certain steel alloys.
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As can be seen, s1 which is the initial wall thickness of the workpiece is reduced to s0.
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B. Avitzur, Handbook of Metal-Forming
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2. A roller makes the sheet metal wrap the mandrel so that it takes its shape.
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Fig. 1. A shear formed product: a hollow cone with a thin wall thickness
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Before the 1950s, spinning was performed on a simple turning
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Figure 2 shows the schematics of a shear forming process.
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Importance of shear forming operations in manufacturing
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true strain below 0.5, the spinnability depends on the
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66:Learn how and when to remove this message
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29:This article includes a list of general
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224:During flow forming, the workpiece is
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141:Workpiece and roller tool profiles
35:it lacks sufficient corresponding
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124:Fig. 2. Shear forming schematics
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50:more precise citations.
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684:Tools and terminology
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513:Progressive stamping
329:Metal Forming Videos
589:Finishing processes
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258:. Retrieved
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602:Galvanizing
442:Sheet metal
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226:cold worked
48:introducing
674:Metallurgy
617:Patination
437:Piece work
260:2008-10-14
236:References
116:Schematics
31:references
669:Machining
664:Jewellery
632:Polishing
597:Anodizing
574:Soldering
488:Extrusion
178:ductility
704:Category
679:Smithing
569:Riveting
564:Crimping
533:Spinning
518:Punching
503:Stamping
689:Welding
659:Forming
649:Casting
627:Plating
622:Peening
579:Welding
559:Brazing
538:Swaging
528:Sinking
523:Rolling
493:Forging
468:Drawing
458:Coining
425:General
412:Forming
197:ironing
44:improve
33:, but
110:lathe
97:. In
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