www.tjprc.org SCOPUS Indexed Journal editor@tjprc.org COMBINING CONVENTIONAL SPINNING WITH WALL THICKNESS REDUCTION IN ONE PASS ESSAM K. SAIED 1 , S. Z. EL-ABDEN 2 , AYMAN A. ABD-ELTWAB 1 M. ABDEL-RAHMAN 2 & M. N. EL-SHEIKH 1 1 Department of Mechanical Engineering, Beni-Suef University, Beni-Suef, Egypt 2 Department of Mechanical Engineering, Minia University, Minia, Egypt ABSTRACT The thin wall cup products are largely used in industries, it is usually made by a conventional spinning process to produce the cup shape, followed by wall thickness reduction process (Flow Forming) to reduce the cup wall thickness. In the present work a new compound tool was developed to perform both processes of conventional and flow forming spinning in the same stroke. The new compound tool consists of two rollers to perform the conventional spinning process followed by two balls to perform the flow forming process at the same stroke. The rollers and the balls are mounted in the jaws of lathe four jaw chuck. The rollers are mounted on two opposite jaws at the same level. The balls are mounted on the other two jaws in another level following the rollers level by about five millimeters. The main advantage of the compound tool is reducing the product cost by reducing the manufacturing time by about 40%. The other advantage of the new compound process is that when comparing it to other processes like incremental forming or single point incremental forming we found that it does not need a special machine or a CNC machine, but it can be conducted on a conventional lathe machine. The new tool was experimentally tested by conducting many compound processes using the tool to produce a thin wall cup. The experimental work verified the success of the new tool. KEYWORDS: Conventional Spinning, Ball Spinning, Flow Forming, Compound Spinning Tool & Thin Wall Thickness Cup Received: Dec 14, 2018; Accepted: Jan 05, 2019; Published: Jun 08, 2019; Paper Id.: IJMPERDJUN2019150 INTRODUCTION Metal spinning is the process of forming a flat metal blank into the shape of the cup by means of manual or hydraulic tool as rollers. This process is performed by tension and compression forces effect on the blank at the same time to produce axisymmetric hollow parts (Heinz Tschaetsch 2004). The spinning process in its original type does not includes any intended thickness reduction. The main types of spinning as mentioned by Boljanovic are manual or conventional spinning, shear spinning, and tube spinning (BOLJANOVIC 2004). Another classification of spinning process named the two types of power spinning and flow forming as types of spinning process(Bewlay 2006; Semiatin, Force, and Directorate 2005). Many developments for the spinning process were conducted, mentioned here the Single Point Incremental Forming[SPIF]process which has the ability of forming asymmetric shapes and conducting a small wall thickness reduction relative to the draw angle at the same time (Jeswiet et al. 2005). Jeswiet et al. concluded Original Article International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001 Vol. 9, Issue 3, Jun 2019, 1429-1436 © TJPRC Pvt. Ltd.