Effects of over-roll thickness on cone surface roughness in shear spinning

A high quality of cone surface finish was achieved by carefully controlled over-roll thickness in the shear spinning process. In this study, blank thickness, roller nose radius, mandrel revolution, roller feed and over-roll thickness were taken as major process variables to investigate the effects of the above parameters on the surface roughness of cone shape products. From the experiment, several sets of experimental data were obtained, which in turn were used to construct regression equations for applied forces and product surface roughness. The results were verified by four extra spinning experiments. It is found that deeper over-roll combines with the thinner blank sheet, larger roller nose radius and slower roller feed, and are advantageous for obtaining smoother surface roughness. Over-roll of the blank in shear spinning is an effective way to improve the surface roughness of the product.