KEVOS® MAKEOS · Fabrication
Shear Spun Cone Plan (Blank, Reduction, Roller Force, Power, Time)
What blank do I need to shear spin this cone, is the thickness reduction within what the material will take, and is the lathe powerful enough?
Plan for shear spinning a cone: blank thickness by the sine law and the thickness reduction (as the shear spinning tool) against the largest reduction the material will take in one pass, blank diameter and mass, tangential roller force, surface speed and power at the roller against the machine, and the spinning time over the cone length at the roller feed.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Wall thickness of the spun cone | mm | Wall thickness the spun cone must have. |
| Half angle of the cone | ° | Half angle of the cone measured from its axis. |
| Large diameter of the cone | mm | Diameter of the large end of the cone (the blank diameter in shear spinning). |
| Small diameter of the cone | mm | Diameter of the small end where the cone meets the mandrel nose. |
| Average flow stress of the material | MPa | Average flow stress of the material over the reduction. |
| Material density | kg/m³ | Density of the material. |
| Process and limits | ||
| Roller feed per revolution | mm/rev | Axial feed of the roller per spindle revolution. |
| Spindle speed | rpm | Spindle speed. |
| Largest reduction in one pass | % | Largest thickness reduction the material takes in one pass (from your spinning trials). |
| Machine power at the spindle | kW | Power available at the spindle. |
Method and formulas
- Blank thickness T = t ÷ sin α; reduction = 1 − t ÷ T (as the shear spinning tool).
- Tangential force = flow stress × (T − t) × feed; power = force × surface speed at the large diameter (as the shear spinning tool).
- Blank diameter = large cone diameter; cone axial length = (D_l − D_s) ÷ 2 tan α; time = length ÷ (feed × rpm).
- Example: use a 4 mm blank 300 mm across (0.76341 kg); reduction 50%; 1.885 kW; 51.962 s to spin.
Limitations
- Ideal sine-law deformation; real forces include friction and redundant work.
- Single pass; larger reductions need intermediate annealing or two passes.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Plan the blank for a spun cone
- Check whether a cone can be spun in one pass
- Estimate the spinning time and power
Who it is for
- Metal spinners
- Fabrication engineers
- Process planners
What you get
- Blank thickness, diameter and mass
- Reduction against the limit
- Roller force, power and spinning time
Interpreting the result
- Small cone angles need very thick blanks and large reductions: they may need two passes.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1362–1364. Topic reference; no source tables or recommended settings are reproduced.
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Open the Shear Spun Cone Plan (Blank, Reduction, Roller Force, Power, Time) calculator
