Metal Forming

Spinning

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning

Metal spinning is cold forming process in which blank metal appears to

flow some what like piece of clay on patters wheel

Metal spinning, also known as spin forming or spinning or metal

turning

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Steps in spinning
Step1: Metal Forming
Involves the laying down of the material onto the mandrel.
Material gets easier to form as part is closer to completion

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Steps in spinning
Step2: Trimming
Parts having been spun are trimmed at end of blunt sharp edges also to
bring the component to the desired length
Step3: Finishing
Finishing is done at very high RPM (1200+) so that a minimum of force
need to be applied and very smooth strokes can be used
The flat side of Duckbill spinning tool is used for straight surface and
rounded side for curves and radii.

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Metal disk or cylinder rotated at high speed on CNC LATHE or on hand by
using specially designed tools get axially symmetric products
Where do use this ?
To manufacture low cost prototype metals
Bell shaped curved are ideal for spinning as metals can deform smoothly
around them
Easy to create concentric ribs to strength part
Almost All metal in sheet form can be spun
Specially used when the product require mirror shine

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Mandrel

The mandrel is form over which sheet metal blank is formed

Can be machined from variety of materials wood being cheapest
Mandrel can also be made of mild steel or aluminum when close tolerance are
required
It is important to design the mandrel with at least 1 degree draft angle so that
part can be removed from the mandrel after spinning
Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Tools
Tool are provided with long handles to ample leverage to work material
down the mandrel
Tools can be up to 3 feet long with 1 inch dia steel rod forged into the
preferred tool tip
Spinning shop make use of tools with rollers mounted on long handle

Department of Mechanical Engineering ,BVCOE & RI Nasik

Metal Forming

Spinning
Lubricants
Lubricants are essential in all metals spinning operations, regardless of the
perform shapes of type of metal spinning tools that are being used
Facilitates easy removal of part from the mandrel & also improve the surface
finish of finished components
Parts are lubricated both before & during the spinning operations
Commonly used lubricants includes wax , tallow's , soaps & grease

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Metal Forming

Spinning
Machines for spinning
Machines for spinning's are specified by the diameter and lengths of
largest component that can be spun
They are also specified by maximum load that can be applied to the work
The capacity of spinning machines ranges from 0.455 m in dia & 0.380 m in
lengths to 6m dia & 6m in length
Metal spinning machines can be both vertical and horizontal
Mostly lathe based machines tools ( both conventional & CNC based) are
employed for spinning operations
Most modern machines used for spinning are at least semi automated that is
they are loaded and unloaded by operator but entire spinning cycle is
controlled by automatically.

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Spinning
Machines for spinning

Schematic diagrams of vertical arrangement employed for

spinning of large dia cone
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Metal Forming

Spinning
Spinning Machines

Photograph of a horizontal lathe, work piece,

and mandrel arrangement for spinning large diameter
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Metal Forming

Spinning
Spinning Machines

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Metal Forming

Spinning
Spinning Machines

Photograph of a 4m dia cone & dish

shaped components produced by the
Leifeld company
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Metal Forming

Spinning

Advantages

Provides natural metallurgical benefits with refined & strengthened grain structure
Cold working of metal also increases tensile properties appreciably
Unlike casting a spun part will not be discarded by hidden blow holes
A spun shell could be made halves and welded to form a single unit without
complex expensive tooling
The tooling cost and capital investment are relatively small
The setup time is less
Design changes in the work piece can be accommodate at relatively low cost
Can be easily automated and is an effective production method for prototypes as
well as high production runs
Since there is no removal metals by formation of chips, there is no material
wastage and the process is economical
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Metal Forming

Spinning
Limitations
Requirement of highly trained operator in manual spinning process for the
uniformity of the product depends to large degree on skill of the operator
Manual metal spinning is usually significantly slower than press forging
Deformation loads allowable much lower in metal spinning than in press
forging

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Metal Forming

Spinning
Applications
Bases, baskets, basins, and bowls
Bottoms for tanks, hoppers, and kettles
Canopies, caps, and canisters
Housings for blowers, fans, filters, and flywheels
Ladles, nozzles, orifices, and tank outlets
Pails, pans, and pontoons
Cones, covers, and cups
Cylinders and drums
Funnels and horns
Domes, hemispheres, and shells
Rings, spun tubing, and seamless shapes.

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Metal Forming

Shear Spinning

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Metal Forming

Shear Spinning

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Metal Forming

Shear Spinning
In conventional spinning, the roller tool pushes against the blank until it
conforms to the contour of the mandrel
In shear spinning, the roller not only bends the blank against the mandrel, it
also applies a downward force while it moves, stretching the material over the
mandrel.

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Shear Spinning

S1 S 0 sin
Where
S1= final wall thickness
S0= starting wall thickness
Alpha angle= inclined angle of mandrel

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Shear Spinning
Advantages
Good mechanical properties
This process widely used in the production of light weight items
Very good surface finish
Dimensional accuracy
Applications
Typical components produced by mechanically powered spinning machines
include rocket nose cones, gas turbine engine and dish aerials

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming

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Metal Forming

Flow forming
Flow Forming is an incremental metal forming technique in which a disk or
tube of metal is formed over a mandrel by one or more rollers using
tremendous pressure
The roller deforms the work piece, forcing it against the mandrel, both
axially lengthening and radially thinning it
During flow forming, the workpiece is cold worked, changing its mechanical
properties, so its strength becomes similar to that of forged metal
Flow forming is a modernized, improved advanced version of metal
spinning
Flow forming subjects the workpiece to a great deal of friction and
deformation

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming
In flow forming; a hollow axis
symmetric preform is fitted to a
mandrel. After both are made to
rotate,
are

compression

applied

to

the

forces
outside

diameter of the preform by

hydraulically-driven

or

ballscrew-driven
controlled

rollers.

CNCFor

most

applications three rollers are

used

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Metal Forming

Flow forming
Forward Flow forming
In forward flow forming, a tailstock
is used to fix the preform to the
mandrel.
The elongation of the workpiece
during forward flow forming is at the
same direction with the relative axial
movement of the rollers.

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming
Backward Flow forming
In backward flow forming, a toothed
ring is used to fix the preform to the
mandrel and it is also used for
reloading of the finished work piece.
The elongation of the work piece
during backward flow forming is at
the opposite direction to the relative
axial movement of the rollers

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming
Forward flow forming

Backward flow forming

Material flow take place is same direction

feed of roller

Material flow take place is opposite

direction feed of roller

Forward flow forming is uniform

dimension across the length of the
product

Backward flow forming is normally prone

to non uniform dimension across the
length of the product

Production is slower in forward

Production is faster than forward spinning
spinning because the roller must
transverse the finished length of the work
piece.
Forward flow forming is suitable for long
high precision thin walled components

Backward flow forming is suitable for

without base blanks or internal flanges

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Metal Forming

Flow forming
Three roller used for flow forming

These rollers have precalculated radial and axial offsets between each
other to achieve necessary forming conditions.

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming
Final component length can be calculated

L0 S 0 (d i S 0 )
L1
S1 (d i S1 )
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Metal Forming

Flow forming
Materials Used in Flow forming
Stainless Steel,
Carbon Steel
Maraging Steel
Alloy Steel
Precipitated Hardened Stainless Steel
Titanium
Inconel
Hastelloy
Brass
Copper
Aluminum
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Metal Forming

Flow forming
Advantages
Chipless, seamless and cold manufacturing.
Highly Precise, seamless construction to net shapes
Improved mechanical properties
Tubular, conical & contoured geometry
Uniform axially-directional, and stable grain micro structure
Better surface finish
Very high diameter-to-length ratio
Repeatable accuracy part-to-part & lot-to-lot

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming
Limitations
The flow forming process is limited to forming radially symmetrical
hallow parts such as cones and cylinders.
Flow forming reduces the ductility and elongation of the material and
spring back may be problem with some results.
Not competitive with deep drawing for long production runs accepting
even when counter are complexes.
Tooling cost for flow forming are lesser than for drawing, but advantage
is lost in long runs because of longer operation time per piece.

Department of Mechanical Engineering ,BVCOE & RI Nasik

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Metal Forming

Flow forming

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Metal Forming

Flow forming

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Metal Forming

Flow forming
Spinning

Flow forming

Used pivoted pointer to push the a

metal sheet mounted one end of the
spinning mandrels

Hydraulic rollers are used to form the

tube

Thickness reduction is minor

Thickness reduction can be

maintained different at different places

Roller deform the w/p axially

lengthening only

Roller deform the w/p both axially

lengthening & radial thing

Axisymmetric thin walled light weight

domestic product such as saucepan
and cooking pots

Widely used to fabricate hollow tubes

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