Experimental implementation and analysis of robotic metal spinning with enhanced trajectory tracking algorithms

Metal spinning is a plastic forming process in which a disk or tube of metal is rotated at high speed and forced onto a mandrel. It is widely used in industry as an efficient, modern and economical production technique. This research proposes to develop a versatile robotic forming method and expand the application areas of robotic manufacturing processes to the metal spinning area. A lathe-type laboratory setup has been built and an industrial robot manipulator has been used to implement the metal spinning process. Experiments have been conducted with enhanced cascaded trajectory tracking algorithms with an add-on vibration suppressor. The potential of the proposed method has been illustrated with extensive case studies using both constant and variable speed trajectory profiles. Analyses for the growth of wrinkles have been performed through the topographical measurements of the products and the forming forces have been inspected. Results indicate that the efficiency of the process can be significantly improved with suitably selected variable speed trajectory profiles and the process parameters. The developed scheme successfully reduces the excessive oscillations of the manipulator during the metal spinning process and it requires no additional hardware to employ. The investigations demonstrate the feasibility of robotic metal spinning using an industrial serial link manipulator. ► Metal spinning is an efficient and economical plastic forming process. ► A versatile robotic forming method has been developed with this research. ► A lathe-type setup has been built and an industrial manipulator has been implemented. ► Enhanced trajectory tracking algorithms have been developed and tested. ► Feasibility of robotic metal spinning process has been validated experimentally.