What is the Advantage and Disadvantage of Metal Spinning Materials

Metal spinning, also known as spin forming or spinning or metal turning most commonly, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part.[1] Spinning can be performed by hand or by a CNC lathe.

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The metal spinning trade is one that dates back to antiquity and was a skill used in the Ancient Egyptian era. This is when metal spinning was limited to soft metals spun by human power on primitive lathes. The technique gave significant advances to hydro and steam power in Europe and North America in the 19th century and by the early 20th century the electric motor provided the necessary power and high-speed turning capability. With this advancement, metal spinning craftsmen were now able to spin higher quality pieces made out of brass, copper, aluminum and even stainless and cold-rolled steel.

Metal spinning does not involve removal of material, as in conventional wood or metal turning, but forming (moulding) of sheet metal over an existing shape.

Metal spinning ranges from an artisan's specialty to the most advantageous way to form round metal parts for commercial applications. Artisans use the process to produce architectural detail, specialty lighting, decorative household goods and urns. Commercial applications include rocket nose cones, cookware, gas cylinders, brass instrument bells, and public waste receptacles. Virtually any ductile metal may be formed, from aluminum or stainless steel, to high-strength, high-temperature alloys including INX, Inconel, Grade 50 / Corten, and Hastelloy. The diameter and depth of formed parts are limited only by the size of the equipment available.

The spinning process is fairly simple. A formed block is mounted in the drive section of a lathe. A pre-sized metal disk is then clamped against the block by a pressure pad, which is attached to the tailstock. The block and workpiece are then rotated together at high speeds. A localized force is then applied to the workpiece to cause it to flow over the block. The force is usually applied via various levered tools. Simple workpieces are just removed from the block, but more complex shapes may require a multi-piece block. Extremely complex shapes can be spun over ice forms, which then melt away after spinning. Because the final diameter of the workpiece is always less than the starting diameter, the workpiece must thicken, elongate radially, or buckle circumferentially.[1]

A more involved process, known as reducing or necking, allows a spun workpiece to include reentrant geometries. If surface finish and form are not critical, then the workpiece is "spun on air"; no mandrel is used. If the finish or form are critical then an eccentrically mounted mandrel is used.

"Hot spinning" involves spinning a piece of metal on a lathe while high heat from a torch is applied to the workpiece. Once heated, the metal is then shaped as the tool on the lathe presses against the heated surface forcing it to distort as it spins. Parts can then be shaped or necked down to a smaller diameter with little force exerted, providing a seamless shoulder.

The basic hand metal spinning tool is called a spoon, though many other tools (be they commercially produced, ad hoc, or improvised) can be used to effect varied results. Spinning tools can be made of hardened steel for use with aluminum, or from solid brass for spinning stainless steel or mild steel.

Some metal spinning tools are allowed to spin on bearings during the forming process. This reduces friction and heating of the tool, extending tool life and improving surface finish. Rotating tools may also be coated with a thin film of ceramic to prolong tool life. Rotating tools are commonly used during CNC metal spinning operations.

Commercially, rollers mounted on the end of levers are generally used to form the material down to the mandrel in both hand spinning and CNC metal spinning. Rollers vary in diameter and thickness depending the intended use. The wider the roller the smoother the surface of the spinning; the thinner rollers can be used to form smaller radii.

Cutting of the metal is done by hand held cutters, often foot long hollow bars with tool steel shaped/sharpened files attached. In CNC applications, carbide or tool steel cut-off tools are used.

The mandrel does not incur excessive forces, as found in other metalworking processes, so it can be made from wood, plastic, or ice. For hard materials or high volume use, the mandrel is usually made of metal.[1]

Several operations can be performed in one set-up. Work pieces may have re-entrant profiles and the profile in relation to the center line virtually unrestricted.

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Forming parameters and part geometry can be altered quickly, at less cost than other metal forming techniques. Tooling and production costs are also comparatively low. Spin forming, often done by hand, is easily automated and an effective production method for prototypes as well as high quantity production runs.[1]

Other methods of forming round metal parts include hydroforming, stamping, forging and casting. These other methods generally have a higher fixed cost, but a lower variable cost than metal spinning. As machinery for commercial applications has improved, parts are being spun with thicker materials in excess of 1in (25mm) thick steel. Conventional spinning also wastes a considerably smaller amount of material than other methods.

Objects can be built using one piece of material to produce parts without seams. Without seams, a part can withstand higher internal or external pressure exerted on it. For example: scuba tanks and CO2 cartridges.

One disadvantage of metal spinning is that if a crack forms or the object is dented, it must be scrapped. Repairing the object is not cost-effective.

• Curling (metalworking)
• Shear spinning

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Many businesses and consumers are often stunned when asked about Metal Spinning. Regularly we hear “What is Metal Spinning?” “How can Metal Spinning benefit my Business?” This blog post aims to address these questions, the first in brief, the second in a little more detail by highlighting the advantages and then the disadvantages.

Metal Spinning, sometimes called Metal Forming, is a unique process we like to refer to as an ‘art’. It’s been used since the time of Ancient Egypt and has advanced with technology to fulfil the needs and requirements of modern industries of today. The process itself requires a sheet metal disc, rotating at high Rotations per minute (RPM) and is formed over a tool, usually made from a Metal or Wood, to create the desired shape. For a more detailed post on Metal Spinning read The Ultimate Guide to Metal Spinning.

Metal Spinning is widely used in industries from lampshade design displayed in retail outlets to components for military use in the Defence Industry. And there are many advantages when choosing a metal spinner to supply components for your business. There are many advantages your business can benefit from when choosing to use a Metal Spinning company such as ours, to supply components for your supply chain. These include the following;

The Metal spinning process produces less waste and is considered the most conservative metal forming process with materials in comparison to forging, stamping, casting etc. This is because the metal spinning process uses the entire sheet metal disc. The waste product of the metal itself occurs during the cutting stage (to produce the metal disc from sheet metal), Cutting (during the spinning process) and Deburring. The leftover metal scraps, however, are then sent off to be recycled and therefore reused.

If your business values an Economically Efficient supply chain, then you should consider using a Metal Spinning business. Especially as the UN Sustainability Development Goals (SDGs) are now being incorporated into many businesses.

Tooling costs are low, this is because tools can be crafted in relation to the life expectancy of the job function it is designed for. For example, if you were to order a one-off order, we would produce the tool out of wood. For long life orders, the tool would be produced using hardened D2 steel. This is more expensive than a wooden tool, but your business will save more money on tooling costs with a one-off purchase. The alternative would be to purchase numerous wooden tools which would not be cost effective.

We provide tool storage as part of our service for up to one year of the last order. This further saves costs and time when it comes to your next order for long-term orders.

In comparison to conventional casting and stamping, Metal Spinning is much less costly due to the simplicity behind tooling. Furthermore, the fabrication processes within Excell that compliment Metal Spinning further saves costs, providing a complete manufacturing solution to your metal spinning needs.

For more information, please visit Metal Spinning Materials.