Influence of process parameters on wedging-spinning of conical cup parts with bottom flanges

Abstract The wedging-spinning process is an advanced incremental forming process for producing conical cup parts with bottom flanges. In this study, the principle of the wedging-spinning process was introduced, based on which the wedging-spinning molds were designed. The process experiments and orthogonal simulation tests were performed. The effects of process parameters on forming force, relative elongation of the wall, and arch height were investigated, and corresponding theoretical explanations were made. The experiment and simulation results were in good agreement with each other. The nose radius has no significant effect on all the three dependent variables. The feed ratio has a significant effect on the forming force. The dip angle of the roller affects the forming force and relative elongation of the wall. There are significant effects of the spinning thickness on all three variables. The arch height reflects the quality of the spinning parts. The spinning thickness is the factor deciding the arch height. Increasing the dip angle and nose radius will reduce the arch height. The research results can provide guidance and theoretical basis for parameters selection when producing conical cup parts with bottom flanges.