Processing maps for wrinkle free and quality enhanced parts by shear spinning

An experimental investigation was conducted to study the effects of key processing parameters when shear spinning conical part geometries from both aluminium alloy and mild steel disc shaped blanks. It investigated the effects of feed ratio, spindle speed, initial blank thickness, and thickness reduction on the occurrence of the wrinkling failure, effectiveness of thickness reduction, part springback, surface finish, and strain hardening effects resulting from the process. A design of experiments approach was used to conduct the experimental tests and a multi-variate regression analysis method was applied to obtain processing maps of the key parameters which produced wrinkling free and quality enhanced spun parts. The results showed that the feed ratio was the most critical processing parameter, with higher feed ratios led to the onset of wrinkling failure, less effective thickness reduction, more part springback and rougher part surfaces. The process was shown to result in a significant strain hardening effect in the blank material, which was found to be enhanced when the amount of blank thickness reduction was increased.