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

Aqeel Bedan,ِِAmmar Saleh,Aseel Abd

doi:10.30684/etj.v39i9.1974

Abstract

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.

Highlights

Spinning of sheet metal is known as a process that transforms circular flat metal blank sheet into an axisymmetric, hollow shapes part by using a forming tool that forces a blank onto a mandrel
Dimensional accuracy error comparison analysis for rectangular spun parts The comparison has been done between the two patches by using Siemens NX 10 software, the analysis data from the comparison where the number of the points checked was 104 points depends on the 12 points in both U and V patch direction and the distance with angular tolerance were chosen to be 5 mm for all the checked parts depends on the nature of spinning process especially when the absence of the supports or mandrel part
The results manifested that the maximum average of error in dimensional accuracy is 6.47 %, for rectangular spun parts, where were observed the big effect parameter was the diameter of the ball tool, where the effect percentage reach 32.43 %, for rectangular spun parts

Summary

Introduction

Spinning of sheet metal is known as a process that transforms circular flat metal blank sheet into an axisymmetric, hollow shapes part by using a forming tool that forces a blank onto a mandrel.

Objectives

Methods

Findings

Conclusion