In this paper, the eccentric cone tube process planning was investigated by using single point incremental forming (SPIF) and prefabricated hole cutting operations. The SPIF with iso-parametric spiral tool path was used for the forming of cone surface and hole flange of the eccentric cone tube. An end mill cutter was used to mill the required prefabricated hole before the flange forming process. A variety of the eccentric cone surfaces can be modeled as a ruled surface or Coon’s surface. Then the iso-parametric spiral tool path can be calculated by using the information of the surface parametric equations. Several eccentric cone tube forming experiments were carried out including aluminum alloy and stainless steel sheet metal materials with WC forming tool. The manufactured cone tubes have a satisfied surface quality and geometric shape on both cone surface and hole flange in which all the residual spiral tool marks reveal smoothly and uniformly. The results show that the present process planning can be applied to manufacture eccentric cone tubes successfully.
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