Chapter - 2

FUNDAMENTALS OF
FLOW FORMING

"A wise system of education will at least

teach us how little man yet knows, and
how much he has still to learn "

.... Sir John Luhbok

 Chapter - 2
FUNDAMENTALS OF FLOW FORMING

Flow Forming is comparatively a recent trend in metal working. It can be defined as a

volumetric, high energy rate, rotary forming process of plastically deforming the metal to the
shape of a rotating mandrel by applying considerable force through one or more power
assisted rollers. The process is employed in accurate manufacture of rotationally symmetric
hollow parts of any desired contour and carried out on a specialised form of lathe fitted with
hydraulic drives and copying (or contour tracing) device. More recently, NC and CNC
systems have been introduced to transfer the skill from the machine operator to the
machine itself with a view to increase the speed, accuracy and consistency of flow
formed products.

2.1 HISTORY OF EVOLUTION

Flow forming is an improved derivative of an old established sheet metal forming

process known as spinning. The principle of conventional spinning might have been
originated many centuries ago when the first potter's wheel was used in Egypt [1]. It is
said that at the beginning of the tenth century, the art of metal spinning used to be applied in
China as means of making hollow vessels from sheet metals [2]. From these distant
beginnings, this art of spinning progressed gradually through the Dark ages, the
Renaissance and the Industrial Revolution, - and today it provides the basis for a new
technique of forming metal in cold state.

The process was introduced into Europe sometime in fourteenth century and after a
period of nearly five hundred years, the craft was taken to USA in or about 1840 [3]

In its beginning, the art was carried out on relatively simple equipment using stick
type wooden hand tools for manufacturing almost exclusively the useful hollow wares

5
and similar items, mostly domestic utensils and general household articles such as water
mugs, bowls, vessels etc. [4]. This hand spinning method was practised only on thin gauge
materials of softer grades such as copper base alloys, and a very high degree of skill and
considerable experience were required of the operator [4].

Subsequently for spinning thicker gauge materials requiring greater power to drive
the machine and application of greater force to the tool by the operator, provision was made
for some form of power assisted tools (rollers) to supplement the strength of the operator, -
and such was the beginning of Power Spinning. With the development of machinery
during the industrial revolution of 19th century, means were available to spin metal with
power assisted rollers, the first known development being a German Patent in the late
1860's[5].

Use of adequate power to assist the forming rollers provided the means for plastic
deformation of metal to aid in obtaining desired shape and extensive development work took
place in the technique of heavy duty power spinning almost simultaneously in several
countries, namely, Sweden (since 1930), Germany (1940), England (1946) and USA (1947) in
order to meet highly stringent demands of accuracy, finish and improved mechanical
properties of many vital rotationally symmetric hollow parts required in various fields of
industry, particularly in the field of gas turbine engine, aircraft, atomic & space research and
armament and defence besides many general industrial applications. This resulted in
appearance of a new metal working technique that referred to here as Flow Forming [5,6].

The machine tool industry varied design features of lathes and vertical boring mills
with hydraulic and electronic controls to produce the flow forming machine in use today [5].
Several machine designs were marketed concurrently and a variety of names were given by
various machine-makers or by the countries practising the process, such as power shear
spinning, hydrospinning, flow spinning, roll forming, spin forging, shear forming, flow
turning, flow forming, etc [4, 7], Of these names, the popularly adopted ones are flow turning
and flow forming.

6
 Eventhough a derivative of old established conventional spinning, the technique of
flow forming today is capable of producing parts to such a close limits of accuracy, precision
and surface finish that can never be dreamed of in the parent process of orthodox spinning.
This is a typical example of the offspring outgrowing the parent.

2.2 PHYSICAL CONCEPTS & DESCRIPTION OF THE PROCESS [1, 2, 7, 8]

As already mentioned, several names are given to the process of flow forming by
various machine manufacturers or by the countries practising the process, such as power
shear spinning, hydrospinning. flowspinning, roll forming, shear forming, spin forging,
flow turning, flowforming etc. Out of these names, the author feels that the name "Flow
Forming" is best suited since it neither connotes a particular manufacturer, nor it indicates
any cutting operation and is adequate to describe the process in which the workpiece metal
is plastically deformed to flow into a new form. However, to remove the confusion, it
would be better to clear the concepts of two associated processes, namely :-

(a) Conventional Spinning

(b) Flow Forming

2.2.1 Conventional Spinning

In conventional metal spinning, a flat circular sheet metal blank of diameter greater
than that of the finished part is held by pressure between a small disc mounted on the tail-stock
and a mandrel mounted on the head-stock of a spinning lathe. The mandrel is rotated alongwith
the metal blank and the pressure is applied on the unsupported portion of the rotating blank
either manually by a stick type hand tool supported by hinged bracket in the case of Hand
Spinning (Fig. 2.1), or by hydraulic power applied through the roller in the case of
Power Spinning (Fig. 2.2) in order to deflect the unsupported portion of the blank metal
and gradually force it over the rotating mandrel by a series of strokes. The number of strokes
or intermediate passes of the roller depends on the thickness and ductility of work material
and also on the ratio of the supported to unsupported diameter of the blank. In both hand and

7
[HEAD STOCK

\ POINT

Fig 2.1 :Schematic sketch showing

conventional hand—spinning of
a hollow metallic conical p a r t

3
 FLAT BLANK

Fig.2.2 : Schematic sketch showing

conventional power spinning
of a hollow metallic cone

9
power spinning, there is no intentional reduction in the thickness of the blank metal and during
the spinning process the metal-flow follows nearly the laws of equal surface area, i.e. the
superficial area of the finished spun part is same as the area of the blank from which it is
made. The limiting factor is the ratio of the blank diameter to the finished part diameter which
should not exceed the value of 1.5, otherwise the circular blank inclines to form folds
during spinning.

2.2.2 Flow Forming

Flow forming is a further development of conventional power spinning. In flow

forming, a metal blank or preform of the same diameter as the maximum diameter of the
finished part is formed over a rotating mandrel. While the blank metal and the mandrel
(which are locked together) rotate, the forming roller follows the mandrel contour
maintaining a preset gap. This gap between the mandrel and the roller acts as an orifice
through which the metal is flowed (extruded). In this manner, the blank or preform metal is
plastically deformed to mandrel contour and proper (reduced) wall thickness following nearly
the principle of equal volume. Fig. 2.3 shows schematically the flow forming of a simple
conical part from a flat round blank metal.

Compared with drawing operation in which the part is formed as a whole, the part in
flow forming is shaped by increment forming. The process must not be confused with
swaging or upsetting operations, since the metal is not reduced in diameter as in swaging or
gathered to increase thickness as in upsetting. In a sense, it utilises a 3-dimensional variation
of the basic rolling process and combines rolling, shearing and bending in one operation [3]
and essentially it is a point deformation metal forming process.

2.2.3 Comparison with Conventional Spinning

Upon first consideration it may appear that the process of flow forming is quite similar
to conventional power spinning process because both the processes have certain commonalities
in that they are normally cold forming methods, they are chipless machining or forming

10
:HEAD STOCK
—, —- THICKER FLAT
_ | -TBLANK

Fig.2.3(a) : Flow forming of a hollow conical p a r t

schematically shown

11
 STARTING
MACHINE HEAD STOCK
POSITION

T h e u p p e r heilf i n d i o a t e a s t a r t i n g p o s i t i o n with
m e t a l b l a n k b e f o r e f o r m l i i g , -while t h e l o v e r half
• h o i r a t h e e n d p o s i t i o n a f t e r flo-w f o r m i n g t h e coni

Fig.2.3(b) : Scheme for flow forming t h e hollow

pointed cone.

12
operations carried out on specialised form of a lathe and the product formed by both the
processes are generally conical, tubular and curvilinear shaped or their combinations
having rotational symmetry. But similarities end here only and it must be understood that
there are some basic differences between the two processes. Some distinguishing
characteristics of flow forming as compared to conventional power spinning are outlined as
under: -

(1) While in conventional spinning, each element of the blank metal undergoes
radial displacement from its original position, there is no appreciable change
in the radial position of each element of the finished part from its initial
position in the blank in the case of flow forming.
(2) Unlike the conventional spinning in which the blank diameter is considerably
greater than the finished part diameter, the blank diameter in flow forming is
exactly same as that of the finished part overall diameter.
(3) Whereas there is practically no intentional thinning of metal in conventional
spinning, a large reduction in metal thickness is accomplished in flow forming.
This means that the metal for the finished part in flow forming is obtained not
from the diameter of the blank as in conventional spinning, but from the
thickness of the blank.
(4) The metal flow during conventional spinning follows nearly the law of equal
surface area, the superficial area of the blank metal and the finished part being
equal, but the metal flow in flow forming follows mainly the principle of
equal volume, the surface area of the finished part being more than that of
the blank metal.
(5) In contrast to the conventional spinning which is essentially a bending and
flaring operation, the flow forming is a point deformation squeezing operation
in which the metal undergoes plastic deformation in a very small region of
work material in contact with the forming rollers.
 (a) CONICAL (l») TUBULAR

(e) CURVILINEAR

Fig.2.4 : Three basic catagories of p a r t s

produced by flow forming process

14
2.3 PROCESS CHARACTERISTICS [9, 10, 11, 12, 13]

The parts produced by flow forming process may be broadly divided into three
basic categories, namely, conical shapes, cylindrical shapes and curvilinear shapes, or
combination of these as shown in Fig. 2.4.

2.3.1 Conical Shapes

The basic shape on which the flow forming process is founded is the cone. Based
on this conical shape, simple formulae have been evolved to determine the thickness of the
flat circular blank required to produce a desired wall thickness of the cone or alternately, to
determine the wall thickness of the cone which will result from a given thickness of the blank.
The formula known as the "Sine Law", is expressed as

t = T sin a

or, T = (see Fig 2.5)

sin a

Where T = thickness of the blank

t = wall thickness of the conical part
a = angle subtended by the wall of the cone and the centre line, i.e. one
half the included cone angle.

Fig. 2.5 also provides an explanation as to the axial displacement of the material in
the process and illustrates that the original thickness of the flat blank is transposed parallel
to the centre line. The limiting value of the angle a is generally accepted as 15° i.e. a cone
with an included angle upto 30° can be flowformed. For producing cones of smaller included
angles than 30* a second flowing operation will be required or, alternately, a pre-machined
blank may be used The necessary formula may be written as

15
Fig.2.5 : 'Sine latv' as applied in flow forming of cone

16
 f\

SECOND STAGE FIRST STAGS BLANK

TJ—Tjptxijcx/mixijS

Fig.2.6 : Method for second stage flow forming

17
 T2 sin a
Tl= . ~ (see Fig 2.6)
sin p

where Ti = thickness of the wall at the first flow form or preform stage.
T2 = wall thickness of the final produce (cone shaped)
a = one half of the included cone angle of the first flow formed cup blank or
preform
P = one half of the included cone angle of the final product

From the forgoing formula, the following mteranees may be drawn :-

(i) The depth of any conical part produced by flow forming is not only dependent
on the blank diameter (as in deep drawing or conventional spinning), but also
on the blank thickness. The blank diameter is, in turns, dictated by the major
(overall) diameter at the open end of the finished cone (including any flange) to
be flowformed.

(ii) The included angle of the finished conical part and the thickness of flat starting
blank (for any specified normal thickness of the wall of the finished part) are
dependent on each other. However, the bottom thickness as well as the axial
thickness of the finished cone remain same as the original thickness of the
starting blank.

(iii) It is not possible to reduce the metal thickness on conical parts other than in
a single pass of the forming roller at the same angle. To carry out more than
one flowing operation, if necessary, additional mandrels will be required with
tapers to the newly calculated included angles and the machines must be
reset for these angles.

The conical parts with varying wall thickness can be produced by using proformed
blanks as shown in Fig 2.7.

18
 PREFORMED BLANK

lis
VARYINg WAT.T, THICIQ>rE3S
Tfe
j&
11 — Tj • i n «

t - 2 — T 2 «iia.a

Fig.2.7: flow forming of a conical p a r t with

varying wall thickness

J9
2.3.2 Cylindrical Shapes (From Flat Circular Blanks)

Based on the two preceeding formulae, it would be a logical assumption that flow
forming of parallel walled cylindrical parts from the flat starting blank is an impossible
task, as the sine of zero degree is zero which means that a blank of infinitely large thickness
would be required to produce even an infmitesimally thin wall thickness of the finished part.
However, the flow forming of parallel walled cylindrical parts from the flat circular blanks
can be accomplished by first forming a shallow cup and then flowing operation can be
carried out at a single pass by using a specially designed dual purpose forming roller
provided that the following conditions are complied with.

(a) d/D> 0.60, and (b) T/D>0.01

Where d = inside diameter of the finished cylindrical part

D = diameter of the initial flat blank
T = thickness of the flat blank

The relationship for combined cupping (by spinning) and cylindrical flow forming is
shown in Fig. 2.8.

2.3.3 Cylindrical Shapes (From Cylindrical Blanks)

Cylindrical shapes or tubular parts with thin wall can be flowformed by starting with a
cylindrical blank (preform) machined, extruded, fabricated or forged which are shorter in
length and greater in thickness than the finished parts, but with the same basic inside diameter
This particular process, also called sometimes as "Flow Turning" or "Tube Spinning", does
not follow the sine law as applied in the flow forming of conical parts but depends
primarily on the volume displacement relationship. The formula in common use for
determining the size of the cylindrical blank may be written as L.T.d.t. = \X.AX

20
 ^

d T
% 0.6 * 56 O . O l
D D

-Ik
Fig.2.8 : Relationship for combined cupping
(by spinning) & cylindrical flow forming

2]
 SINE LAW N O T APPLICABLE
DEPENDS ON VOL. DISPLACEMENT RELATION
L.T.(<A.T) — l.t.(d.t)
MULTIPLE —PASSES PROCESS
2 0 - 6 0 5 5 THICKNESS REDUCTION AS PER N o . OF ROLLERS

Fig.2.9 : Volumetric relationship in flow forming

of cylindrical shapes

22
 It (d . t)
L= x v(see Fie.
& 2.9)
T (d.T) '

Where L = required length of the cylindrical blank

1 = length of the finished cylinder
d = inside diameter of both cylindrical blank and finished cylinder
T = wall thickness of cylindrical blank
t = wall thickness of finished cylinder

The ratio (d.t) / (d.T) is a correction factor which can safely be ignored when flow
forming large diameter cylinder with very thin walls.

Flow forming or flowturning of cylindrical or tubular parts may be accomplished by

one or both of the two methods, namely, "forward flowing" or backward (reverse) flowing".

Fig. 2.10 illustrates the technique of forward flowing (drawing type) where the metal
is flown ahead to the forming roller and in the same direction as the roller feed. During
forming the deformed metal is in tension and the undeformed metal in front of the roller is
essentially stress free. This technique provides excellent control of length especially since
the metal is moved only once during the flowing pass.

Fig 2.11 illustrates the technique for backward or reverse flowing (extruding type)
where the metal is extruded beneath the forming roller and in opposite direction of the
roller feed. The underformed portion ahead of the roller is in compression and the deformed
metal is essentially stress free. This method saves considerable time as shorter roller feed is
required to form the same finished length. Other benefits include shorter mandrel, longer
parts than the machine travel and simpler tooling

The flow forming of cylindrical parts is generally a multipass process in which the
part becomes thinner and longer with each pass of the forming rollers. There is no
mathematical formula for optimum deformation However, as a general rule, a machine with

23
 * M e t a l tlovrm a h « a d of r o l l e r - In. ma m i direction
a e roUer- f e e d .

S x o e l l a n t c o n t r o l of l a n g t h , metal being ra.O'voA

o n l y o x i o e ixx f ollo-frlrxa p a a a

f=^^^
E3-
I I Znl
/"A

FEED

Fig.2.10 : Technique of forward flow forming of t u b e

24
 Metal la extruded beneath roller in opposite
direction of roller feed.

Shorter mandrel, pert longer than the slide

travel, time savins method

Ln
i i

B
• '

W 71

FEED

Fig.2.11 : Reverse flow forming technique

for tubular p a r t s
 * G r a d u a l t i i l n n i n f j o f TVO.11
* A m o u n t o f d e f o r m a t i o n d e f i n e d fay a i a x n e S i n e 1
* C o n t o u i — - t r a c i n g d e v i c e -with t e m p l a t e required
(to s y n c h r o n i s e axial and radial feed)
VARYING TTAUL T H I C K N E S S UNIFORMLY .THICK BLANK

ti —T eina

t 2 -T -in,.

t- -T sa<

^ 7

Fig.2.12 : Flow forming of curvilinear (spherical)

shape of varying -wall thickness from flat
blank of uniform thickness

26
 1*! —t/elncc!

T
3 -t/ilnog

FLOTTFORMED PART

UNIFORM "WALL THICKNESS

Fig.2.13 : Flow forming of curvilinear (parabolic)

shape of constant wall thickness from a
contoured blank

27
a single roller is capable of taking 20% to 30% reduction in thickness per pass while the
machines with two or more rollers may take 40% to 60% reduction per pass. Total
reduction in thickness which is possible upon a given part is dependent primarily upon the
percentage reduction and the work hardening characteristics of the material of the part.

2.3.4 Curvilinear Shapes

Curvilinear shapes (parabolic, half elliptical, hemispherical etc) can be flow

formed either from flat blanks resulting in a gradual thinning of wall (Fig. 2.12) or from the
taper/contoured blanks giving a constant wall thickness of the finished part (Fig. 2.13). The
optimum amount of deformation in a given part is defined by the same sine law. In
flowforming of curvilinear shapes, a contour-tracing (hyro-copying) device or attachment
with suitable template to synchronise the axial and the radial feeds of the forming rollers is
required to be used. Today it is easily done on CNC flow forming machines.

2.4 PROCESS PARAMETERS

The objective parameters or end results characterising the process such as flow
formability, improvement in mechanical properties, dimensional accuracy and surface
finish as well as power requirement of the machine are influenced by various controlling
input parameters as outlined under :

2.4.1 Process Variables

(a) Surface speed of forming (normally ranges from 300 to 600 m/min).
(b) Longitudinal feed or forming roller axial travel rate (normally in the range
from 0.5 to 1.25 mm per revolution).
(c) Deformation rate or percentage reduction in metal thickness per pass (should
not exceed 75%).
(d) Coolant and lubricant used at the interface of the workpiece and the rollers

28
2.4.2 Preform or Blank Quality

(a) Preform symmetry (should be within 0.06 mm).

(b) Thickness and thickness variation (variation should not exceed 0.05 mm).

2.4.3 Tool Geometry

(a) Mandrel shape, accuracy and finish

(b) Edge radius (r) and contact angle (5) of the forming rollers (normally r = 2-2.5
times thickness reduction, 8=15° to 40 ).

2.4.4 Work Material

(a) Hardness, strength and ductility

(b) Purity and cleanliness
(c) Microstructure

2.5 ADVANTAGES OF FLOW FORMING

2.5.1 Saving in Material

Flow forming, a volumetric forming process, "moves" rather than "removes" material.
Since the scrap losses in the form of chips are practically eliminated, tremendous savings in
material are realised. Simple blanks can be axially flown into complex forms eliminating, in
many cases, the need for expensive machining, welding or deep drawing operations.

2.5.2 Improved Part Quality

Cold working during flow forming refines, elongates and reorients the grain structure
of the finished parts in the direction of flow (parallel to the part contour), resulting in
substantial increase in the tensile strength, yield strength and hardness In some cases, part

29
strength is increased as much as 100%, thus offering the opportunity of replacing expensive
high strength material with lower cost material. Moreover, flow formed parts have high
resistance to fatigue failure. Despite high forming pressures employed in the process, the
surface have no ruptures, tears or fractures

2.5.3 Good surface finish & dimensional accuracy

Surface finish on the inside diameter of a flowformed part is a direct reflection of the
mandrel finish but the surface finish on outside diameter, depending upon various controlling
parameters or variables, generally range from 0.8 to 1.6 microns which is comparable to
commercial grinding finish.

The process is capable of producing ID. and wall thickness tolerances of ± 0.05
mm. However, the stable repeatative accuracy of the work is depended to a large extent on
the tolerances of the starting blank or preform, the accuracy of the mandrel, the rigidity of the
machine and how closely the forming roller follows the mandrel

2.5.4 Low tooling cost

The basic tooling for flow forming consists of a mandrel, forming roller and tracing
template. This simplified tooling generally cost a fraction of what is required for
conventional metal forming process (e.g. about one-tenth of the tooling cost for deep
drawing operation), and has a long life under normal operating conditions.

2.5.5 Less finished scrap

Serious flows or foreign inclusions in the workpiece material are often revealed during
flow forming operation. This early discovery in material imperfection reduces further
processing which is a decided saving since the flaw or even part failure, in case of other
processes, would normally not be detected until final inspection.

30
2.5.6 Design Freedom

Flow forming offers a greater opportunity to the creative designer and

development engineer for alternate practical solution to his design. The combination of
advantages such as material saving and low tooling cost promotes experimental and
prototype work by flowforming.

2.6 LIMITATIONS OF FLOW FORMING

Some of the major limitations of the flow forming process are as follows :

(a) The process is restricted to the manufacture of hollow axisymmetrical parts.

(b) The thickness of the metal that can be flowformed today is limited to 25 - 30 mm
with about 60% reduction in wall thickness per pass.
(c) Spring back of material after flow forming may be a problem which can be
minimised by increasing the roller feed rate, thereby compromising with desired
surface finish of the part.

2.7 APPLICATIONS OF FLOW FORMING

Prior to its wide spread adoption in about the year 1953, flow forming was used
principally in the manufacture of utensils, kitchen ware, precision television tubing etc.,
which were of thin sections. Now much heavier sections are flow formed easily. Rocket
motor tubes, warhead casing, cartridge cases, which were hitherto manufactured by
conventional spinning and other production processes, are now being produced by flow
forming technique. In aeronautical industries, certain critical items of jet engines are made by
this process. For space research, sections and large size parts are being flow formed, and flow
forming process has been playing an important role in the manufacture of critical
components for defence, aerospace as well as industrial applications. For space research
applications where strength to weight ratio is of utmost importance, the application of flow
forming is inescapable

31
 It is not possible to list out in detail the applications of flow forming because the
types of components that can be effectively manufactured by this process are enormous. It is
sufficient to mention a few as in Fig. 2.14 just to give an idea.

2.8 FLOW FORMESG MACHINES [3, 4]

A flow forming machine, in its simplest form, may be considered to be a specialised

form of lathe fitted with hydraulic drives, forming rollers and contour tracing devices.
More recently CNC systems have been introduced to transfer the skill from the machine-
operator to the machine itself with a view to increase the efficiency of operation as well as the
accuracy and precision of the flow formed products.

All machines for flow forming of metals work on the same basic principle but may
differ in design from one machine-manufacturer to another. Fig. 2.15 shows a schematic
line diagram of a horizontal flow forming machine which consists of the following main units:

1) A sturdy & rigid base on which are mounted all the important units like
headstock, tailstock, carriage, main bed, etc.
2) Headstock complete with drive unit
3) Tailstock & hydraulic unit
4) Carriage main Bed/slide way
5) Carriage (with separate hydraulic power pack) which carries the roller heads
fitted with forming rollers.

The most commonly used machines are of horizontal type. However, one major
drawbacks of the horizontal models is the very large floor space requirement. Therefore,
some manufacturers have gone for vertically designed machines to conserve valuable floor
space. Ofcourse there are certain components, which for various reasons would not be
practical to be flow formed in vertical orientation, and for these components, vary large
honzontal type machines are suitable

32
Fig. 2.14 : Some typical components produced by
flow forming process

33
 Flow forming machines are available with single forming roller, or two forming rollers,
or even three rollers, the selection being dependent on the types of components to be
produced. As a guideline, for simple axi-symmetric components requiring not very high
accuracy & consistancy, the single roller machines can serve the purpose. However, for high
degree of accuracy and surface finish as well as for maintaining tight geometrical
tolerances, the two-roller or three-roller machines are more preferable respectively for flow
forming of conical parts and cylindrical parts.

Fig. 2.16 to Fig. 2.18 show the pictorial views of a number of flow forming machines
of different types and models made by various manufacturers of the world, whereas Tables
2.1 to 2.3 list out their important technical specifications.

Table 2.1 : Technical Specifications of Flow Forming Machine

Make : M/s. Kieserling & Albrecht Gmbh & Co., Solingen, Germany

Technical Data Model Model Model

AS 23.40 AS 23.60 AS 24.50
Machine Type Horizontal, Two Rollers, CNC
Max. Parts Dia (mm) 500 900 1000
Drive Motor :
(i) Main Spindle (kW) 45 110 74
(ii) Hydraulic (kW) 30 74 45
Spindle Speed (rpm) 120 90 90
(Variable thro' DC drive motor) to 1200 to 900 to 900
Feed Force :
(i) Longitudinal slide (fcN) 200 250 240
(ii) Cross slide (kN) 120 500 180

Table 2.2 : Technical Specifications of Flow Forming Machine

Make : L&F Industries, USA

Machine Type Horizontal, Single Roller

Machine Size (inches) 26x20 45x20 60x30
Work swing (inches) 26 45 60
Work length, maxe (inches) 20 20 30
Travel main-slide (inches) 20 20 30
Travel cross-slide (inches) 14 22 30
Spindle drive motor (h.p) 10 20 30
Force per slide (lbs) 4000 8000 8000
Net weight (lbs) 6500 17000 14000

34
 P-RTV-TC MOTOR
WORK MKTAL

CARRIAQE WITH ROT.T.FiR HEAD

Fig.2.15 : Schematic sketch of a two—roller flow

forming machine

35
Fig. 2.16 : A Single Roller Flow Forming Machine
(Leifeld & Co, Germany)

Fig. 2.17 : A Three Roller Flow Forming Machine

(Leifeld & Co., Germany)

36
Fig. 2.18 : A horizontal two rollers CNC flow forming machine
& its control panel
(M/s. Kieserling Albrech Gmbh & Co,
Germany Model 23.40)

37
Table 2.3 : Technical Specifications for Leico Range of Flow Forming Machines
Make Leifeld Und Co., Germany
Type Horizontal, Auto/CNC, One/Two/Three
Rollers
Parts Diameter (mm) 30/400,60/560, 100/650
Longitudinal slide travel, max (mm) 400,800, 1300,2400
Feed Force (longitudinal & cross) (kN) 70,90, 150,300,400
Motor Rating
(i) Main (kW) 22, 30, 75, 90, 132
(ii) Hydraulic (kW) 18.5,30,55,120
Speed Range :
(I) 9-12 steps (rpm) 36-365, 195-975,200-1200
(ii) Infinitely variable (rpm) 220/820, 165/500
Overall Weight (kg) 9000, 11000, 15000,32000

2.9 MECHANICS OF FLOW FORMING OF CONES

Metal working processes may broadly be classified into two basic categories. These
are :
(1) Chip forming; i.e. conventional machining
(2) Chipless forming, i.e. metal forming

In the first category of processes, the shape of the workpiece consisting of a metal or alloys is
altered by removing unwanted metal from the workpiece, whereas in the second category of
processes, the workpiece shape is altered by plastic deformation of the workpiece metal. Thus,
in the chip forming or conventional machining processes, it is mainly the waste metals or chips
that are plastically deformed, whereas in the chipless forming or simply metal forming processes,
it is the workpiece that is subjected to plastic deformation.

2.9.1 Classification of metal forming processes

Numerous metal forming processes are now employed in metal working industry and
there is no general agreement in their classification. One of the best ways to classify them is
based on the states of stress according to which the processes may be grouped into three
categories [16] :

38
 Table 2.4 : Classification of Major Metal Forming Processes

(A) SQUEEZING MECHANISM

APPROX, INSTANTANEOUS
FORMING PR0CES5
5R. STATE OF ZONE OF 5TRTE OF'"/.-

No STRESS RT DEFORMATION DEFORMATION

NAME DIAGRAM 50URRE (CR055 HATCHED)

1 CLOSED DIE
V/HOLE
FORGING
(DROP OR PRESS:
*§& fsf- PRRT
N0N5TEPDY

rT WHOLE
COINING NON5TERDY
PART

WHOLE
UPSETTING N0N5TERDY
PRRT
(OPEN DIES)

UPSETTING Wc
WHOLE
All t ~ & - NONSTERDY
(CLOSED DIES! PRRT
ULi
EXTRUDING ZONE
FLATS I ROUNDS
(DIRECT OR FORVflflQ)
roS J7.AC w& - ^
NEPR
ORIFIC
STEADY

liir S
EXTRUDING ZONE
FLATS & ROUNDS' '7//. NERR STEADY
'/,
(1H01RF.CT OR nnCKVPRO) ORIFIC
EXTRUDING 1 ZONE
HOLLOW SHAPES
(REVERSE CANNING)
J=4
'/V V/r
UNDER
PUNCH
NONSTERDY

ROLLING FLATS,
ROUNDS I OTHER
SHAPES (V1TH0UT
• *
fe
& •
er
ZONE
UNDER
ROLLS
STEADY
FRONT I FJflCK PULL)
FLOW F O R M I N G
I ZONE
OF TUBES
(EXTRU01MG TYPE)
r •Cf UNDER
ROLLER
STEADY

FLOW FORMING tfi. ZONE

OF TUBES
(EXTRUDING TYPE)
> £? UNDER
ROLLER
STEADY

ZONE
FLOW FORMING
OF CONES
'"I
W UNDER
POLLER
5TFADY

ZONE
0 SWAGING AND
• \3" UNDER NONSTERDY
KNEED ING / TOOLS
 Table 2.4 : Classification of Major Metal Forming Processes

(B) DRAWING MECHANISM

RPPROX. IN5THNTANE0U5
FORMING PROCESS
SR. 5TRTE OF ZONE OF STATE OF
No. STRESS RT DEFORMATION •'• DEFORMATION
NAME DIAGRAM 5QURRE ICR055 HUTCHED)

WIRE & BAR

DRRWING -E| • & -
ZONE IN
DIE
STEADY

TUBE DRRWING
1_ ZONE IN
STEADY
- ^ DIE
"^

DEEP DRAWING
WHOLE NON5TERDY
OF CUP5,B0XE5
wk
I OTHER SHAPES m & FLANGE

EMBOSSING
L* ZONE IN
(HL50
Ex DIMPLING)
BENDING
~£p- DIE
CAVITY
NONSTEADY

<<N-.^
STRETCH WHOLE
NONSTEADY
& ~
FORMING PART

r MUUUEIl

BULGING /A •• J\ ///
1 j f
ZONE
DIE
IN

NONSTEADY
CAVITY

ZONE
ROLL
A. /7
te
BETWEEN STEADY
V
FORMING
"V V ^6T R0LLE5
 Table 2.4 : Classification of Major Metal Forming Processes

(C) BENDING MECHANISM

APPROX. IN5TRNTRNE0U5
FORMING PR0CE55
5R. STATE OF ZONE OF STRTE OF

No. 5TRE55 RT OEFORMflTION DEFORMATION

NAME DIAGRAM SOURRE (CR055 HnrCIIED)

IN BEND
' 1 STRAIGHT LiLL.^ AND IN N0N5TEADY
FLANGING ^ ~
FLANGE

2 STRAIGHT IN BEND
FLANGING
(CONCAVE
FLANGES )
^
-r AND
FLANGE
IN NON5TERDY

41
 (a) Squeezing operations in which materials are principally subjected to
compressive loading.
(b) Drawing operations in which materials are principally in tension.
(c) Bending operations in which moments must be applied, thereby
inducing tension on one side of the part while compression on the other side.

Table 2.4 illustrates the major metal forming processes under the above classifications.

2.9.2 Category of Flow Forming

Flow forming is one of the recent fttocesses- falling under the category of squeezing
operations. Instead of forming a part as a whole (as in deep drawing operations), the part is
shaped in flow forming by incremental forming. Thus flow forming is essentially a 'point
deformation' metal forming process. The deformation takes place in a small region where
the roller contacts the workpiece, i.e. the instantaneous zone of plastic deformation is the
zone under the roller with a steady state of deformation as shown at serial No. 8 under
Squeezing Mechanism in Table 2.4.

2.10 REVIEW OF THEORETICAL ANALYSIS & MECHANICS OF

FLOW FORMING

Because of the difficulty of applying exact mathematical methods to the problems of

interest in flow forming technology, only approximate methods of solution are employed in
analysing the mechanics of plastic deformation in flow forming. There are a number of
approximate methods for treating the flow forming problems, but none of the solutions is
perfect because of the fact that by necessity assumptions are required that may only very
generally describe the physical behaviour and the mechanism of the system. Furthermore,
some solutions will give average stresses and strains whereas others give local distribution. In
fact, the precise state of stress and mechanics of plastic deformation in flow forming is still
ill-defined. Thus in the analysis of a flow forming problem, no categorical guidance can be
given, although some useful hints and tips are often possible to be obtained from several
research papers appeared on the subject. It appears that flow forming of hollow axi-

42
symmetric sheetmetal parts has no doubt aroused considerable interest among the research
workers since more than three decades Paulton & Colding [18] considered flow forming of
hollow cone as a combination of bending and rolling process, whereas Kalpakcioglu
[19] assumed a simple shear mechanism for the theoretical analysis. The complex
straining effect was introduced into the solution by Avitzur and Yang [20] and also by
Kobayashi et al [21], More recently, Slater [22] has given approximate upper bound
estimates for the dimensionless tangential force component.

2.10.1 Deformation Energy Method

Deformation mechanism in flow forming of cones is shown schematically in Fig.

2.19. The initial blank thickness (T) and the final wall thickness of the cone (t) for the half-cone
angle ( a ) are related by the equation

t= Tsina (2.1)

In view of the complexity of the actual deformation process, several analytical solutions
for basic quantities such as forces or power requirement in flow forming based on
varying approximation and simplification has been proposed. All these solutions utilise the
deformation energy method.

Ideal Process :

Kalpakcioglu [19], assuming the flow forming of sheet metal cone as a simple shear
mechanism, proposed an idealised process as shown in Fig. 2.20. The analysis is like the model
of a deck of cards sliding over each other which has been widely used in metal cutting with a
single point cutting tool. The difference here is that the elements in Fig. 2.20 are concentric
hollow cylinders sliding over each other axially and forming a hollow cone while at the same
time fulfilling the requirements of eqn (2.1). It can be easily seen from this figure that the
shear strain is the distance an element moves axially divided by the thickness of the element.
Therefore, the expression for the shear strain is

43
R I) t
0 II
0 • 0
L c ?<? L
?xC 0 EE|Eo
•x "0 0 »;
• • *
£ E E o Ev
B-0 0
0 • r "a 5 JC •H a
c
o» a
" E ^5 S • •0 0

= 8
"11 o
• B • • C
«
C 0 0 0
L
c «
CP 0 I.
- r-5 £= = ic - ou w - v
0>
u a *- 0 ' 0 0 0 c » C I

II I I II I g
0 L
I O DO 0 U
GO

2- O
r d CO
o
O ^

^°
o2
Bo*
to 5
SB «t-i w
O
So
O cy o
WT3

cvi

44
 y = cot a (2.2)

This is for the case where the flange is straight, i.e. 8 = 90°. If the oiriginal blank is preformed
such that the preform half angle 8 has a value between 90° and 0°, the expression for the shear
strain becomes

y = cot a - cot 6 (2.3)

Kalpakcioglu [24] has further shown that strain rates occuring during average cone
forming conditions vary from 102 to 6.5 x 102 per second depending on the roller corner
radius or 'lead-in'. These rates approach that experienced in impact loading. As a result,
actual allowable deviation from the 'sine law' is quite limited.

From eqn. (2.3), it can be easily seen that for the same mandrel half angle a, the
greater the preform angle the less will be the value of shear strain. For this ideal case, the
roller cones radius r is taken as zero.

For a strain hardening material, shear stress x will be a function of shear strain y.
Furthermore, since T Vs. y curves of materials are more scare than a Vs..8 curves, it
would be better to use the relationship between y and s from the deformation energy theory
which may be written as

y = V3 E

y l
or e = ~ = - (cot a - cot 6) (2..4)
V3 3
where s is the principal true strain in a tensile test.

If closely examined, it will be noted that the axial thickness of the elements in the
region under roller changes. However, the measurement of actual parts flow formed
with different values of r (roller corner radius) have shown that the variation in axial thickness
from the original blank thickness is within ±10% At this point, it would be interesting to see

45
how well the idealised process agrees with the actual flow pattern of a metal formed by the

process.

Kalpakcioglu [26] who used the methods of plugged holes and grid line techniques,
observed that the original blank is twisted about the axis of the mandrel during flow forming
process. This distortion is not uniform in the thickness direction, hence the result is a twisting
of all radial cross-sectional planes.

Force Analysis :

One of the most important parameters in flow forming process is the power required to
carryout a particular forming operation. It has been experimentally observed that while the
axial and radial forces in flow forming may be much larger than the tangential force
component, i.e. torque, it is the tangential force that is responsible for most of the power
consumption.

The external work input during flow forming of a hollow axi-symmetric cone can be
closely approximated by F, . dl, where F, is an instantaneous tangential force component
acting on the forming roller and dl is the distance of contact between the roller and the
cone during an infinitesimal time interval dt Equating the external work input to the work
of deformation permits the following energy balance :

f (fj)dl = dv j a d ^ (2.5)

where a and z are effective stress and infinitesimal strain respectively, and dv is the
infinitesimal volume of the cone being flow formed. Therefore the eqn (2.4) can now be
written as

= T sin a f J a ds

or ( F y = T . f. sin a .om . e (2 6)

46
where T is the initial blank thickness, f is the roller feed rate and a is one-half the cone angle.
The mean effective stress am in eqn. (2.5) should be evaluated at the total effective strain s
achieved.

Kalpakcioglu [ 19] determined the effective strain by assuming simple shear deformation
under roller and has given the expression for tangential force Ft as under

c T e - COt a
F, = T » i » sinaon V^
1 (2.7)
i.e. F, = —7= T • f • o" • cos a
V3

where effective strain does not include redundant straining.

Avitzur and Yang [20] used a more sophisticated analysis in determining the strain rate
under the roller. They set up the strain rate tensor components from the instantaneous
velocities under the circular tool. They neglected, however, any redundant straining caused by
repeated passage of the roller over the same metal when the feed is smaller than the extent of
the plastic zone. They derived the following equation for the tangential force F, as

Vl + 5
F, = ( 2 n Ro f cos a + A ) (2.8)
2« V5 • 7 t » R 0

Ro = instantaneous cone radius at contact with roller

f = roller feed
a = half the cone angle

1
= square strain rate ratio
R

47
 A = JA ^ d9
\cnJ
a = mean flow stress
m

n = fraction of revolution swept out during time interval A t

T = initial blank thickness

The quantity 5 involves strain rate ratios which are assumed to be independent of
R and 9 and, together with o Z / c n , can be obtained from the approximate equations of a

torus if the roller is assumed to have this shape. If the strain rates — (du z I 59) are
R
neglected, then 6 is zero, and similarly, if A is assumed to be small compared with 2 n R<, f cos

a then the force eqn (2.8) due to strain rates — ( 5uz / 59) alone reduces to
R
cos a
Ft = a m i f — T ^ - (2.9)
V3
which is same as the simple eqn. (2.6) derived from the shear work of deformation for an
average effective stress.

Kobayashi, Hall and Thomsen [21], assumed in their analysis that the bending takes
place simultaneously with shearing at point P of Fig. 2.21 and is followed by unbending as
the roller passes during each revolution of the cone. They have calculated theoretically the
total effective strain with reference to Fig. 2.21; and evaluated the tangential force Ft from the
simple shear theory.

Kobayashi, Hall, Thomson [21] have also shown that approximate values of the
radial force component Fr and the axial force component Fa can be evaluated from the value of
tangential force component F, assuming that the normal stress p is uniformly distributed over
the contact area between the roller and the cone. A graphical and approximate numerical
method was used by them to get the contact area in the three mutually perpendicular direction
so that for the assumed stress condition
AT- A Q

Fr = F.. — , and Fa = F, — (2 10)

At At

48
 CONTACT
AREA

£ , - DEFORMATION

C O U N T E R OF
FLANGE BEFORE
TO C O M E S INTO T H E
DEFORMATION ZONE

<«>

Fig. 2.21 .Straining of an element in cone spin forging

(a)Tangential section (b)axial section (c)radial section

49
Where Ai\ Aa and At are the three projections of the contact area between the roller and cone in
the three coordinate directions r, z and 0 respectively.

2.10.2 Approximate Upper Bound Estimates for Dimensionless Tangential Force

Flow forming of sheet metal cones is essentially an unsteady state process since the
positions of the elements in the plastically deforming region change as the cone is formed and
the diameter increases. At the same time, for a constant rotational speed of the mandrel, the
forming speed (velocity) of the elements increases from the nose to the base of the cone.
The effects of strain hardening and temperature are also not easy to assess.

Nevertheless Slater & Joorabchian [27, 28] presented an upper-bound estimate for
dimensionless tangential force component assuming (a) plain strain deformation and (b)
axisymmetric deformation by considering single triangular velocity field on a Median plane.

Assuming Plain Strain Deformation, the expression for the dimensionless tangential
component force (Ft / a . T f) has been given as

^-^ + sin2p - sin2«j).sin(p + (|)) + (1-R)

R 1 - R
— sin P . sin <j) sin (P + ()))
a. T. f R
sin2 (P + <j>) sin2 <J>. sinP
1-R
(2.11)
Where f = roller feed per revolution.
T = initial blank thickness
R = fractional reduction in wall thickness [(T-t)/T = 1 - Sin a]
a = average flow stress
P = angle of inclination of roller land to the cone surface.
<)| = angle of inclination of the exit line to the cone surface
The optimum value of (j) which gives a least upper bound estimate was determined for
various values of R.

50
 UPPER—BOUND ESTIMATE
77
AXISYMMETRIC DEFORMATION' /

UPPER—BOUND ESTIMATE
PLAIN STRAIN
DEFORMATION

EXPERIMENTAL
.2 VALUES FOR
70/30 BRASS
(ar~4,SiO MPa)

1 1
O 0.2 0.4, O.O
FRACTIONAL REDUCTION IN T H I C K N E S S (R)
Comparsion of t h e approximate upper—bound
estimates -with experimental values of the
dimensionless tangential component force
70/30 brass

51
Assuming Axi-symmetric Deformation, with straight lines of tangential velocity
discontinuity on a Median plane, Slater [28] obtained the expression for the dimensionless
tangential component force as under :

sin <j). sin P sin |3 R sin (j)

F, _ R (1-R)sin 3 ((3 + (|>) sin <|>. si" (P + 40 (1-R) sin p . sin (p + <>
|)
oTf 2
+ 2(l-R)(l + lnR)

(2.12)

Approximate upper bound estimates for dimensionless tangential component force

as derived by Slater [28] appear to provide acceptable correlation with experimental values
during flow forming of 70/30 Brass sheetmetal cones carried out by him. The values of
dimensionless tangential component force during flow forming of cones as predicted by
approximate upper bound estimates are produced in Fig. 2.22. For the purpose of
comparison, the experimentally observed values obtained by him from flow forming of 70/30
brass sheetmetal cones also included in the same figure.

2.11 LOCALISED DEFORMATION: MAIN ASSET OF

FLOW FORMING PROCESS

One of the applications of large scale deformation using point loads (compressive) is in
the process of flow forming. In other metal forming process such as forging, bending, rolling,
drawing, extrusion, etc., the area of contact between the tool and the work is large, and
therefore, the force and the power requirements is of considerable importance in designing such
metal forming machines. By adopting incremental/point or localised deformation process, the
forces and power requirement can be largely reduced and this technique is accomplished in flow
forming process.

In flow forming process, the deformation takes place in a small region where the forming
roller contacts the work [17]. This trend of localising the deformation zone to a small region of
the work has the following main advantages:

52
(a) large specific pressures are brought into action.
(b) there is a considerable reduction in the forming forces required.
(c) the force characteristic is almost flat and consequently the size of the
machine required to perform the process is reduced.

53