Characterisation and development of the incremental shear forming process for advanced structures

Marine Guillot, Paul Blackwell, Andrzej Rosochowski, Elizabeth Moore, Steven Halliday

Research output: Contribution to conferencePaper

Abstract

Shear forming is an incremental forming process that transforms a starting pre-form in 2D plate condition, into 3D structures of typically conical geometry. Roller(s) shear the pre-form onto a conical mandrel, resulting in a reduction of the starting wall thickness. The benefits of the process can be described in terms of improved material utilisation, enhanced product characteristics, good surface finish, consistent geometric control and reduced production costs. The process has potential application to a wide range of conical geometries used within advanced aerospace structures, which are currently manufactured from bulk forgings, with high associated machining costs. The paper explores the effect of key processing parameters on the formability of 304L stainless steel material, shear formed using an industrial flow forming/shear forming/spinning machine. A Design of Experiments (DoE) approach was used to study the relationship of feed rate, spindle speed and coolant/lubricant systems to the component geometry, surface finish, microstructure and hardness. Regression equations that link the process parameters to the geometry and surface finish were obtained by statistical analysis. Scanning Electron Microscopy (SEM) and hardness testing was used to characterise the shear formed material and enable an improved understanding of the material behaviour throughout the shear forming process.

Fingerprint

Geometry
Hardness testing
Spinning machines
Forgings
Stainless Steel
Formability
Coolants
Design of experiments
Lubricants
Costs
Statistical methods
Machining
Stainless steel
Hardness
Microstructure
Scanning electron microscopy
Processing

Keywords

  • shear forming
  • stainless steel
  • design of experiments

Cite this

Guillot, M., Blackwell, P., Rosochowski, A., Moore, E., & Halliday, S. (Accepted/In press). Characterisation and development of the incremental shear forming process for advanced structures. Paper presented at 13th International Cold Forming Congress, Glasgow, United Kingdom.
Guillot, Marine ; Blackwell, Paul ; Rosochowski, Andrzej ; Moore, Elizabeth ; Halliday, Steven . / Characterisation and development of the incremental shear forming process for advanced structures. Paper presented at 13th International Cold Forming Congress, Glasgow, United Kingdom.
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abstract = "Shear forming is an incremental forming process that transforms a starting pre-form in 2D plate condition, into 3D structures of typically conical geometry. Roller(s) shear the pre-form onto a conical mandrel, resulting in a reduction of the starting wall thickness. The benefits of the process can be described in terms of improved material utilisation, enhanced product characteristics, good surface finish, consistent geometric control and reduced production costs. The process has potential application to a wide range of conical geometries used within advanced aerospace structures, which are currently manufactured from bulk forgings, with high associated machining costs. The paper explores the effect of key processing parameters on the formability of 304L stainless steel material, shear formed using an industrial flow forming/shear forming/spinning machine. A Design of Experiments (DoE) approach was used to study the relationship of feed rate, spindle speed and coolant/lubricant systems to the component geometry, surface finish, microstructure and hardness. Regression equations that link the process parameters to the geometry and surface finish were obtained by statistical analysis. Scanning Electron Microscopy (SEM) and hardness testing was used to characterise the shear formed material and enable an improved understanding of the material behaviour throughout the shear forming process.",
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note = "13th International Cold Forming Congress ; Conference date: 02-09-2015 Through 04-09-2015",
url = "https://www.strath.ac.uk/afrc/coldformingevent/",

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Guillot, M, Blackwell, P, Rosochowski, A, Moore, E & Halliday, S 2015, 'Characterisation and development of the incremental shear forming process for advanced structures' Paper presented at 13th International Cold Forming Congress, Glasgow, United Kingdom, 2/09/15 - 4/09/15, .

Characterisation and development of the incremental shear forming process for advanced structures. / Guillot, Marine; Blackwell, Paul; Rosochowski, Andrzej; Moore, Elizabeth; Halliday, Steven .

2015. Paper presented at 13th International Cold Forming Congress, Glasgow, United Kingdom.

Research output: Contribution to conferencePaper

TY - CONF

T1 - Characterisation and development of the incremental shear forming process for advanced structures

AU - Guillot, Marine

AU - Blackwell, Paul

AU - Rosochowski, Andrzej

AU - Moore, Elizabeth

AU - Halliday, Steven

PY - 2015

Y1 - 2015

N2 - Shear forming is an incremental forming process that transforms a starting pre-form in 2D plate condition, into 3D structures of typically conical geometry. Roller(s) shear the pre-form onto a conical mandrel, resulting in a reduction of the starting wall thickness. The benefits of the process can be described in terms of improved material utilisation, enhanced product characteristics, good surface finish, consistent geometric control and reduced production costs. The process has potential application to a wide range of conical geometries used within advanced aerospace structures, which are currently manufactured from bulk forgings, with high associated machining costs. The paper explores the effect of key processing parameters on the formability of 304L stainless steel material, shear formed using an industrial flow forming/shear forming/spinning machine. A Design of Experiments (DoE) approach was used to study the relationship of feed rate, spindle speed and coolant/lubricant systems to the component geometry, surface finish, microstructure and hardness. Regression equations that link the process parameters to the geometry and surface finish were obtained by statistical analysis. Scanning Electron Microscopy (SEM) and hardness testing was used to characterise the shear formed material and enable an improved understanding of the material behaviour throughout the shear forming process.

AB - Shear forming is an incremental forming process that transforms a starting pre-form in 2D plate condition, into 3D structures of typically conical geometry. Roller(s) shear the pre-form onto a conical mandrel, resulting in a reduction of the starting wall thickness. The benefits of the process can be described in terms of improved material utilisation, enhanced product characteristics, good surface finish, consistent geometric control and reduced production costs. The process has potential application to a wide range of conical geometries used within advanced aerospace structures, which are currently manufactured from bulk forgings, with high associated machining costs. The paper explores the effect of key processing parameters on the formability of 304L stainless steel material, shear formed using an industrial flow forming/shear forming/spinning machine. A Design of Experiments (DoE) approach was used to study the relationship of feed rate, spindle speed and coolant/lubricant systems to the component geometry, surface finish, microstructure and hardness. Regression equations that link the process parameters to the geometry and surface finish were obtained by statistical analysis. Scanning Electron Microscopy (SEM) and hardness testing was used to characterise the shear formed material and enable an improved understanding of the material behaviour throughout the shear forming process.

KW - shear forming

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Guillot M, Blackwell P, Rosochowski A, Moore E, Halliday S. Characterisation and development of the incremental shear forming process for advanced structures. 2015. Paper presented at 13th International Cold Forming Congress, Glasgow, United Kingdom.