Characterisation and development of the incremental shear forming process for advanced structures

Marine Guillot, Paul Blackwell, Andrzej Rosochowski, Elizabeth Moore, Steven Halliday

Research output: Contribution to conferencePaperpeer-review


Shear forming is an incremental forming process that transforms a starting pre-form in 2D plate condition, into 3D structures of typically conical geometry. Roller(s) shear the pre-form onto a conical mandrel, resulting in a reduction of the starting wall thickness. The benefits of the process can be described in terms of improved material utilisation, enhanced product characteristics, good surface finish, consistent geometric control and reduced production costs. The process has potential application to a wide range of conical geometries used within advanced aerospace structures, which are currently manufactured from bulk forgings, with high associated machining costs. The paper explores the effect of key processing parameters on the formability of 304L stainless steel material, shear formed using an industrial flow forming/shear forming/spinning machine. A Design of Experiments (DoE) approach was used to study the relationship of feed rate, spindle speed and coolant/lubricant systems to the component geometry, surface finish, microstructure and hardness. Regression equations that link the process parameters to the geometry and surface finish were obtained by statistical analysis. Scanning Electron Microscopy (SEM) and hardness testing was used to characterise the shear formed material and enable an improved understanding of the material behaviour throughout the shear forming process.
Original languageEnglish
Publication statusAccepted/In press - 2015
Event13th International Cold Forming Congress - AFRC (Advance Forging Research Centre), TIC (Technology & Innovation Center) building of University of Strathclyde, Glasgow, United Kingdom
Duration: 2 Sep 20154 Sep 2015


Conference13th International Cold Forming Congress
Country/TerritoryUnited Kingdom
Internet address


  • shear forming
  • stainless steel
  • design of experiments


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