Design and Validation of Forming High-Precision Cylindrical Components by Three-Roll Flow Forming Process

Flow forming is an incremental metal forming process and is capable of making high-precision cylindrical steel components when the forming rolls and process parameters are correctly designed. Development of flow forming is largely through experimental work and its forming theory is hardly systematic and comprehensive. This paper describes formulation and study of the relationship of the kinematics and kinetics of the flow forming process, which was used as a guideline in establishing process design methodologies and forming procedures of high-precision cylindrical components. The springback mechanisms, material formability and mechanics for establishing stable forming conditions have significant influence on the part quality and were primary subjects in the investigation. These analytical studies were instrumental in the course of engineering and problem solving related to precision flow forming. The selected results from the development are discussed.