Study on die-less spinning of square section cone with fillets

Due to the high flexibility and low cost, die-less spinning has great potential in aviation, aerospace, agricultural machinery, and lighting manufacturing industries. However, forming accuracy will restrict the application of die-less spinning in square section cone with fillets which is often used as the intermediate shape of box parts according to the lack of die support. In view of this, the mathematical analytical method is adopted to design the roller path which contains arc regions and linear regions. The designed roller path is tested and verified through the spinning experiment which was carried out on the PS-CNCSXY 5 spinning machine. The thickness and the radius of the fillets are compared with theoretical values. And the causes of relative errors are analyzed in three different depths. In addition, the stress-strain fields during the spinning process were analyzed by finite element modeling whose creditability was evaluated by using various energy histories. The measurement values of the thickness and fillets radius are basically consistent with the theoretical ones. The feasibility of the die-less spinning method for square section cone with fillets is certificated.