Handbook: The Ultimate Guide To Metal Spinning - RocheIndustry

Metal Spinning Overview

Metal spinning may be a versatile and powerful technique for manufacturers and engineers. Many metallurgists only consider its usefulness for creating small batches of artisanal goods.

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Without metal spinning, motorcycle parts and car wheels wouldn’t be very easy to form. Neither would gas bottles, cooking pots and pans, or myriad components within the defense and aerospace industries.

Read on as I guide you on everything that you should know about metal spinning.

What is Metal Spinning?

Metal spinning is an industrial process that is used for processing metals into a spinning form. The process entails rotating or spinning a disc or tube metal at high speed. As the rotation takes place, the metal is converted into a symmetric part.

Unlike the popular assumption, metal spinning does not involve the removal of the material from the workpiece. Instead, the metal is physically molded into the desired shape with minimal destruction of the material.

Metal spinning can be performed manually or through a CNC lathe machining process. You should also know that there are many different methods of metal spinning while at the same time, different types of metals can be subjected through this process.

The process fundamentals are simple. A round blank, flat or preformed, is fixtured during a spinning lathe. As the blank spins, a roller tool forms around it.

Usually, as the blank is pressed against a mandrel, the grain structure is compressed, producing a smooth surface that always doesn’t require any other form of secondary finishing.

The methods of metal spinning can vary depending on the complexity of the part that is being processed. This also applies to the cost of the metal spinning lathe. Some techniques will attract a higher cost than others.

History Of Metal Spinning

Metal spinning has quite a rich history. It is assumed that the potters’ wheel of the traditional Egyptians provided the idea for the spinning process. This is despite the fact that primary evidence of metal spinning techniques getting used for the forming of metals occurs within the middle ages.

Evidence of the spinning process is also provided by an old wood carving, which shows a metal spinner engaged within the production of what are obviously metal vessels.

Some of the materials that were spun during those ancient days include wood, bronze, stone, amber, among others.

Development to the modern age

The major development in spinning and lathe add the Middle Ages was the introduction of technology that allowed workers to continuously rotate materials.

This technology was mainly attained by replacing the bow with the pedal. Moving the pedal with one’s feet freed the worker’s hands to regulate the speed of rotation and specialize in accuracy and precision.

The lathe unit also became more compact, manifesting as a small disk-shaped station for machining.

The worker stamped on the pedal, or foot treadle, which rotated an outsized flywheel, resetting the action of the treadle and allowed the worker to down thereon as endless action.

Viking and other societies didn’t develop this continuous action until later, although they did use pedal-driven lathes. Here, poles were used to reset the treadle in the lathe, but because this activity reversed the rotation direction, chiseling could only occur during one motion. Pole lathes were easy to supply and really common, even up until the 20th Century.

Eventually, iron lathes were constructed for denser materials. These lathes varied in size but worked similarly to the sooner copper and wooden lathes. Iron lathes might be made very precise, creating a delicate clock and watch parts.

The invention of the electric motor is credited for spearheading the metal spinning industry to a completely new level. It provided the basis for running most modern metal spinners and also made hand spinning redundant. The process can be carried out with total ease.

Industrial metal spinning is done by the CNC machining systems. Apart from increasing the production volumes, these machines are automated and are more accurate.

Metal Spinning Process

Image of metal spinning process source Researchgate.net

How is metal spinning done? Here is a summary of how metal spinning is carried out:

The first step of the process entails mounting a block onto the drive section of the lathe. From there a pre-sized disk-shaped metal is clamped against this clamp with the help of a pressure pad.

The clamped block and the workpiece are then rotated at high speed. Localized or concentrated force is then exerted on the workpiece so that it can flow over the block. Various metal spinning tools generate the force.

Some workpieces are then removed from the block while other complex workpieces are channeled to the multi-piece blocks. More complex pieces are spun over the ice forms.

Regardless of the case, the diameter of the workpiece will always be smaller than the initial diameter when you started working on the piece. This makes it necessary for the workpiece to be thickened or elongated o compensate for the reduction.

Another process known as necking or reducing is done to allow the workpiece to alter its geometries. During the entire process, very little attention is given to the surface finish of the metal.

Hot Spinning

Hot spinning refers to the process of spinning a piece of metal on a lathe while a high beam of heat is directed to the workpiece. After the workpiece is heated, the subject metal is then shaped whereby the lathe is pressed against the heated surface. Necking or reduction of the diameter can still be achieved through the hot spinning technique.

Multipass spinning vs Shear Metal Spinning

Although metal spinning is designed to achieve one common goal, the steps and techniques used are not always the same. This means that there are different iterations of this process.

The most common iteration of metal spinning is the multipass spinning. This is where the roller of the spinning tool rolls over the disc several times shaping your metal so that it takes the shape of the mandrel.

Another common type of metal spinning is known as shear spinning. Here, a part of the metal is finished with just a single pass. The shear spinning roller presses against the metal using a unique technique giving it the desired shape. Shear forming can also be done on a manual machine.

Both the multipass and the shear spinning can be done on the same machine. The difference is the impact that the spinning process will have on the metallurgical metal. Also, both the methods of metal forming have a direct impact on the thickness of the metal.

A Video illustration of metal spinning

Another essential aspect of this metal forming method is choosing the right metal spinning tools. If you are planning to go for the manual metal spinning method, then you should aim at choosing the right tools for the job.

The primary tool for metal spinning is always referred to as a spoon. There are many other improvised tools that can still be used for the job.

Most metal spinning tools are made from hardened steel though there are some that are made from solid brass.

In almost all situations, metal spinning tools are designed to spin on the bearing. This is done with the aim of improving the surface finish of the metal while at the same time increasing the durability of the tool.

As the spinning tool rotates, the heat and friction that are generated during the process tend to be greatly minimized.

In recent years, CNC machines are replacing most tools for spinning due to their high levels of accuracy and efficiency. The rollers that are used in the CNC machines come in different diameters. It all depends on the application of the metal to be spun.

Cutting tools also form part of the CNC tools. They are essential since some metals may have to be cut after they have been spun. A significant percentage of the cutting tools for metal spinning is made of carbide.

Advantages of Metal Spinning

Still, wondering whether you should consider metal spinning services? To bring this matter to a halt, here are the top advantages of spun metal;

Time-saving: Through metal spinning, several metal forming operations can be performed under one operation. This will reduce the time frame that you need for the production process.

Strong metals:  The spun metals tend to be strong, tough, and resilient. This is due to the repeated impact force that these metals are subjected to during the metal spinning process.

Less wastage: As compared to other methods of metal forming, metal spinning does not cause any significant wastage of the material.

Less post finishing process: Spun metals don’t need to be subjected to numerous post-finishing processes.

Versatile: Metal spinning can be used on different types and sizes of metals. You can opt for this method regardless of the size of metal. Also, different shapes can be obtained from this process.

Cost-effective: Metal spinning services are cheaper than most alternative methods of metal forming. You are likely to pay less for quality work. Of course the secrete to this is choosing affordable metal spinning companies.

From this list, it is clear that metal spinning is not something that you can easily ignore.

Metal Spinning Products and Applications

The metal spinning process has a wide range of applications. Basically, you can easily identify products of metal spinning by observing their shapes.

Some of the common shapes of metal spinning include;

-Conical

-Spherical

-Semi-spherical

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-Parabolic

-Venturi

-Cylindrical

-Toroidal

In relation to that, there are different types of metals that are used for spinning. They include;

-Stainless steel

-Copper

-Aluminum

-Carbon steel

-Titanium

-Brass

From the above shapes and lists, we can easily list products such as automotive parts, gas cylinders, satellite dishes, cookware, among others. This list also shows that the applications of metal spinning spread across different industries.

Factors To Consider When Choosing Metal Spinning Designs

Before you go for the metal spinning services, there are certain factors that you should consider if you want excellent work done. These factors include;

-State the functions of your object: The whole design issue will depend on what you are planning to use the product for.

-Choose the right material: There are different types of metals that can be spun. Choose one depending on your needs and requirements.

-Take care of the dimensions of the metal to be spun. This can be diameter, radius, and thickness of the metal.

-Specify the tolerance levels of the metals

-Do a cost analysis to determine the cost of metal spinning

What are the limitations of metal spinning?

Just like other methods of metal forming, metal spinning is not all perfect. Metal spinning is limited to concentric shapes. Also, the process can fail to produce the desired finishes of metals.

With proper consultation from metal spinning experts, such limitations can be worked on easily and effectively.

Metal Spinning Companies in China

Where can I get the best metal spinning services? The best option is to find a reliable metal spinning company in China. By doing this, you can be sure of the quality of the job done.

At Roche Industry, we pride ourselves for being a reliable and affordable metal spinning company in China. We are also an experienced metal spinner thanks to the many years that we have been providing this metal forming service. This is in addition to the modern metal spinning tools that are at our disposal.

We are one of the most versatile metal spinning companies in China. By this, we simply mean that we can spin different shapes of metals. Whether you want discs, hemisphere, or tank heads.

You only need to call us for premium metal spinning services in China.

References

Top 20 Different types of Metal You Need to Know

Handbook: The Ultimate Guide to Metal Casting

White Paper: The Ultimate Guide To Metal Stamping

Handbook: The Complete Guide to Metal Bending

What are the Strongest Metals on Earth?

What’s Difference Between Expanded Metal and Perforated Metal?

Everything You Should Know About Ferrous Metals vs Non-Ferrous Metals

A metal forming press, also known as a stamping press, is a machine tool used to precisely shape and cut metal typically using upward and downward movements. Metal, supplied in sheet, coil, or tube form, is pressed between two halves of a press tool. The top half of the tool, a punch, is attached to the ram, and the bottom half of the tool, a die, is attached to the bolster plate secured to the bed of the press. Posts and bushings are often used to guide the pressing motion.

In general, metal forming is a manufacturing process that reshapes metal by plastic deformation. Metal can be permanently bent, stretched, and compressed into complex geometric shapes with a press. The ability to reshape the metal is proportional to the type and amount of stress applied to the part.

Metal forming presses can be cam driven mechanically, powered via a flywheel and motor, or hydraulically, which uses fluid pressure to exert force during the forming process. Mechanical presses are able to reach high production speeds and are used regularly in assembly plants, however hydraulically powered metal forming presses offer much more versatility. A wide range of press tonnage, forming capabilities, and overall complexity of finished parts can be achieved with the use of hydraulically powered forming presses. Hydraulic presses can be used in a wide variety of applications as a standalone press, in an automated press line, or as a transfer press. For these reasons and more, hydraulic metal forming presses are often found in manufacturing plants around the globe.

Hydraulic presses, also known as Bramah presses after inventor Joseph Bramah, were first developed in the late ’s through his studying of fluid motion. A hydraulic press works by building up pressure within a closed system in order to generate and exert a powerful and steady force throughout the pressing process.

Hydraulic presses, which can be equipped with fully programable electrical control systems, are widely used in metal forming because of their efficiency, versatility, dependability, and the high level of force they are able to generate. They can come in either single or multi-action configurations allowing for multiple tools to be used to accomplish multiple operations simultaneously. Metal forming with hydraulic presses is used for various production applications that can range from large body panels to individual parts used in a wide variety of industries including; automotive, aerospace, packaging, consumer goods, defense, construction, electronics, medical devices, and many more.

Processes capable of forming and shaping metal which can go beyond the capabilities of a hydraulic metal forming press include:

Casting: Metal shapes can be formed by pouring molten metal into a mold, cooled, and then removed from the mold.  A wide range of metal alloys can be cast and complex shapes can be produced.

Rolling: Sheet metal rolling is a process where metal stock pieces are passed through one or more rollers.  Bending, forming, and flattening are a few of the forming processes that can be achieved through rolling.

Fabrication: For prototyping or small production runs, parts can be produced from multiple sheets via welding or other joining processes. In most cases, fabrication is only appropriate when production volume is not high enough justify the cost of dedicated tooling.

Laser Cutting: With the use of a high-powered laser, holes and cut-outs can be burnt through a sheet metal piece.  Laser cutting is a quick and precise metal forming process that can be handled with automated machines.

Spinning: Spinning, also known as spin forming and metal turning, rotates a metal disc or tube at high speed transform it into a desired shape.  Depending on the material to be used, the process can be done hot or cold and produces an axially symmetric part. Cylinders, cones, and more complex geometries consisting of a combination of shapes can be produced via spinning.

A metal forming press can produce extremely complex parts, but the general process can be simplified to a few simple operations; shearing, bending, and stamping. A well configured press with the appropriate tools is capable of achieving a combination of these basic functions with a single stroke of the press. Let’s examine these basic operations, and the considerations of each that will result in a high a quality finished part.

Shearing: Shearing, also known as die cutting is a metal forming process in which straight lines are cut on flat sheet metal stock. A top and bottom blade are typically used to slice through the metal piece.  The top blade will come down and pierce through the part, while the bottom blade remains stationary. The process typically results in clean cuts with smooth edges.  It is a cost-effective method and a wide variety of metal materials are suitable for shearing.  The geometry and material of the tools used in shearing can affect the quality of parts produced. The press speed, use of lubrication, and clearances between tools and workpiece both pre and post shear, are also factors that contribute to process success.

Blanking: A die and punch are used to shear metal, typically in sheet or roll form, to produce flat shapes.  The geometry and size of the final piece is driven by the die and punch used. Blanking is a relatively straight forward, quick and cost-efficient method to produce large volumes of parts. Material waste can be minimized with strategic nesting of parts, and/or left-over metal can be reused for other applications. The process is best used for parts that are simple in geometry. If additional shaping is required, it can be accomplished in subsequent forming operations.

Punching: Punching is similar to the blanking process, however rather than leaving the outside of the part, punching removes material from the inside, like holes, via shearing forces. The metal removed is typically scrapped. A metal forming press can be configured to achieve both blanking and punching simultaneously.

Bending: Bending, a widely used method of forming sheet metal, gives the part an angular shape by deforming it with a punch. The bent metal will undergo a combination of compressive and tensile forces, beyond the material’s yield strength, resulting in the finished part.

Common bending methods including air bending and bottoming, are typically done on a brake press machine. Air bending allows the sheet metal to be bent to a specific angle by setting the stroke of the punch. Materials of different type and thickness can be bent to varying angles without needing to change the punch or die. Bottoming is a similar process, as it also uses a punch and die, however the punch will press the material against the contours of the die to define the bend angle.

Forming forces, accuracy, spring back, adequate bend radius to avoid risk of cracking the material, metal ductility, and material thickness are some of the factors that go into the design of bent parts and configuration of the press.

Deep Draw Presses: The deep draw process can be used to manufacture a wide variety of components such as body components, tanks and cans, cookware, and appliance panels. A deep draw press provides optimal control of pressing forces and material flow during forming, resulting in high quality finished parts with fewer defects compared to other forming techniques. Deep drawing reduces waste and minimizes production costs as the process results in the manufacture of a net shape using minimal material. Assembly costs can also be reduced by redesigning multiple components into one deep drawn part.

Forging Presses: Forging presses can provide precise high-speed performance, offering the optimal press control necessary to produce a wide array of open or closed die forged products for heavy industrial, automotive and aerospace applications such as, flanges, bearings, axles and gears. A hydraulic press can be specifically designed for the hot forging process with appropriate hydraulic and electrical control systems.

The processes discussed so far make up a small set of the types of metal forming that can be achieved with hydraulic presses. The dynamic nature of a hydraulic metal forming press allows for even more capabilities. So how to choose the right one? A large number of factors are involved when deciding on the right press. Technical requirements are very dependent on the specific product to be produced and production forecast. Additional requirements involve the press line itself, integrating into existing production and infrastructure, process control, and the availability of maintenance, service and spare parts for the press. These factors can have a significant impact on the cost of ownership of a metal forming press.

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