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Metal spinning is a plastic forming process for forming rotational shapes. In this process, a sheet metal blank attached to a rotating mandrel is subjected to a force by a roller tool and formed into a desired shape. This process is more suitable for high-mix low-volume production than press forming. Former studies on forming nonaxisymmetric shapes encountered the problem that the shapes were limited to noncylindrical shapes. In this study, we propose a synchronous multipath metal-spinning method for nonaxisymmetric shapes with vertical sidewalls. The tool trajectory changes from the flat shape of the blank gradually to fit the shape of the mandrel surface. Linear interpolation between the blank and mandrel shape along normalized planar paths, which constitute curved- and straight-path elements, is used to calculate the tool trajectory in three-dimensional space. The cross-section shape of the mandrel is measured by touching it with the roller using force control. It is possible to independently handle the mandrel shape, blank shape, and the paths for interpolation in this method. Cylindrical and rectangular box shapes are successfully formed from thin aluminum sheets in forming experiments.

Development of Synchronous Multipath Metal-Spinning Method for Forming Nonaxisymmetric Shapes