COMBINING CONVENTIONAL SPINNING WITH WALL THICKNESS REDUCTION IN ONE PASS

The thin wall cup products are largely used in industries, it is usually made by a conventional spinning process to produce the cup shape, followed by wall thickness reduction process (Flow Forming) to reduce the cup wall thickness. In the present work a new compound tool was developed to perform both processes of conventional and flow forming spinning in the same stroke. The new compound tool consists of two rollers to perform the conventional spinning process followed by two balls to perform the flow forming process at the same stroke. The rollers and the balls are mounted in the jaws of lathe four jaw chuck. The rollers are mounted on two opposite jaws at the same level. The balls are mounted on the other two jaws in another level following the rollers level by about five millimeters. The main advantage of the compound tool is reducing the product cost by reducing the manufacturing time by about 40%. The other advantage of the new compound process is that when comparing it to other processes like incremental forming or single point incremental forming we found that it does not need a special machine or a CNC machine, but it can be conducted on a conventional lathe machine. The new tool was experimentally tested by conducting many compound processes using the tool to produce a thin wall cup. The experimental work verified the success of the new tool.