Shear forming

In shear spinning the area of the final piece is approximately equal to that of the flat sheet metal blank.

The design of the roller must be considered carefully, because it affects the shape of the component, the wall thickness, and dimensional accuracy.

The smaller the tool nose radius, the higher the stresses and poorest thickness uniformity achieved.

Kalpakciouglu concluded that for metals with a true fracture strain of 0.5 or greater, there is a maximum limit for the shear forming reduction.

Since it can achieve thin sectioned parts of almost any shape, shear forming is a versatile process used widely in the production of lightweight items.

Typical components produced by mechanically powered spinning machines include rocket nose cones, gas turbine engine parts, and dish aerials.

[2] During flow forming, the workpiece is cold worked, changing its mechanical properties, so its strength becomes similar to that of forged metal.

Fig. 1. A shear formed product: a hollow cone with a thin wall thickness
Fig. 2. Shear forming schematics