Non-axisymmetric die-less spinning using ball-crown-shape roller

Abstract

The non-axisymmetric cone has broad application prospects. However, the severe wall thickness thinning has been the bottleneck problem restricting the application of non-axisymmetric parts which are manufactured via die-less shear spinning. In order to control the spun wall thickness distribution, the ball-crown-shape roller is adopted to carry out the non-axisymmetric spinning. The spun workpiece with the non-axisymmetric cone shape is obtained, and the deviation of the maximum and minimum half cone angles α and β between the experimental results and the theoretical values is no more than 4.11%. The wall thicknesses are much greater than that of the shear spinning value with the corresponding half cone angles, and basically maintain at (even locally exceed) the initial blank thickness. At the same time, the half cone angle is considered to have small effect on the wall thickness distribution. The finite element model for this spinning process is established and verified to reveal the wall thickness distribution mechanism which is illustrated as that the BCSR causes the complementary relationship between the metal outflow and circumferential replenishment in the each half cone angle direction.