Manufacturing Technology Today

B. Ravikumar ¹, S. Gajanana ¹, K. Hemachandra Reddy ², K. N. Nigam ³

Affiliations
1 M V S R Engg. College, Nadergul, Hyderabad, IN
2 J N T U College of Engg, Anantapur, IN
3 Mechanical Engg Dept, M V S R Engg. College, Nadergul, Hyderabad, IN

Abstract

Metal forming involves deforming of metal plastically into various derived shapes and sizes under the effect of externally applied forces. Flow forming is an advanced, near net shape, chipless metal forming process, which employs an incremental rotary point deformation technique for manufacturing seamless, dimensionally precise, tubular and other rotationally symmetrical products. In shear forming process deformation is carried out by combination of axial and radial forces using a set of rollers thf coordinate retrieval system using AUTO LISP for bottle neck shaped inner shell cylinder of a missile which is used for a critical space application. The experimentation consists of two stages ,i.e. Flow turning of cone with 36º included angle fromat are simultaneously moved along the length of the rotating preform. The present paper discusses on development o input Size blank of 400 x 400 x 16mm and then Spinning of cone to inner shell cylinder by spinning (3 or 4 Passes). The earlier method of development of component was a manual feeding of coordinates. This involves painstakingly measuring distances in the CAD drawing with reference to the equipment, whose axes are at an angle of 120° to one another. This process of manual retrieval of coordinates to be entered require a laborious 18hrs of operator time for every new trial. Auto Lisp, a standard feature of AutoCAD, which enables us to introduce a special command with customized output. A standard program in Auto Lisp, which gives only the end points of a polyline, was re-written to give coordinates of points at every 1 mm. This developed system brings down operator time per cycle from 18hrs to less than 15 min. and also minimizes the human error. After successful execution of the program the coordinate values thus obtained are used for the development of prototype in copper alloy and also in the development of actual material.

Keywords

Metal Spinning, AUTO LISP , Co-Ordinate Retrieval System.

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B. Ravikumar ¹, S. Gajanana ¹, K. Hemachandra Reddy ²

Affiliations
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Department of Mechanical Engineering, JNTUA, Anantapuram, IN

Abstract

Sheet metal spinning process is a plastic working technology and is frequently used for manufacturing axisymmetric shapes. Sheet metal spinning has developed significantly and spun products have widely used for various industrial applications. In the current paper a review is carried on finite element simulation of multi-pass spinning with different path profiles and multi-domain techniques of simulation process. It is also proposed scope for new tool geometries for metal spinning process.

Keywords

Metal Spinning, Multi-Pass, Simulation, Multi-Domain.

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B. Ravikumar ¹, S. Gajanana ¹, K. Hemachandra Reddy ², G. Rahul Teja ¹

Affiliations
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Department of Mechanical Engineering, JNTUA, Anantapuram, IN

Abstract

Metal forming involves deforming of metal physically into various derived shapes and sizes under the effect of externally applied forces. Flow forming is an advanced, near net shape, chip less metal forming process, which employs an increment rotary point deformation technique for manufacturing seamless, dimensionally precise tubular and other rotationally symmetrical products. Spinning is an advanced continuous and local 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 also has the possibility of producing parts that could not be deep drawn. Initial workpiece shape is either a flat blank or a preformed hollow component. 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 workpiece. 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 spinning force is developed using full factorial design of experiments conducted on Aluminum 2024-T3 sheets with parabolic mandrel. Contribution of each factor on output is determined by Analysis of Variance (ANOVA).

Keywords

Metal Spinning, Factorial Design of Experiments, ANOVA, Spinning Force.

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B. Ravi Kumar ¹, S. Gajanana ¹, K. Hemachandra Reddy ², P. V. K. Chaitanya Kumar ¹

Affiliations
1 MVSR Engineering College, Hyderabad, Andhra Pradesh, IN
2 AP State Council for Higher Education, Vijayawada, Andhra Pradesh, IN

Abstract

Spinning is widely used metal forming process to fabricate components or products have rotational symmetry. It is a localized metal forming process which is mainly used due to its advantage of high quality associated with low cost for manufacture. In this process a tool is pressed against the rotating pre form of final product. The surface rough ness is one of the important parameters of spun product which are used in aerospace industry. In the present study an investigation is carried out on Al2024 material to get a conical product by adopting Taguchi OA methodology for experimentation. The experiment is carried out by using two different geometry rollers namely single roller and double radii roller at two different rotational speeds on different thickness of sheets as input parameters. The surface roughness is the target response in this investigation. Regression model for surface roughness is developed using MiniTAB software. Further Analysis of Variance was carried out to find the contribution of each parameter on the response.

Keywords

Conical Mandrel, Surface Roughness, Regression Model, Taguchi Method.

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