Investigation on effects of process parameters on surface roughness for spinning process using cylindrical mandrel

Abstract

Flow forming is an advanced, near net shape, chip less metal forming process, which employs an increment rotary point deformation technique for manufacturing seamless symmetrical products. Spinning is an advanced continuous and localized metal forming process, which is widely used in many fields due to its advantages of flexibility, high quality and low cost. It is frequently used for manufacturing axisymmetric shapes where press tooling might not be justified on grounds of size and production volumes. It is characteristic of this process that the deformation does not occur in an annular zone around the axis of rotation but that the tools act upon a much localized area in which plastic flow takes place. During spinning tools are moved relative to the rotating work piece. In this paper, a regression model showing the relation among input process parameters, Mandrel speed (rpm), Roller type and Thickness of sheet (mm) and output (response) as surface roughness (µm) is developed using Minitab Software. The experiments were conducted on Aluminium 2024 T-3 sheets with cylindrical mandrel using Taguchi orthogonal arrays (L9). Further Analysis of Variance was carried out to find the contribution of each parameter on the surface roughness.