Tooling Parameters
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Key tooling parameters include roller diameter and nose radius, mandrel diameter and blank support. Other important factors in tooling selection include production volume, the size of the part and the type of material being deformed. Whether made by the spinning-machine manufacturer or inhouse by the spinner, rollers come in different diameters and radii, both of which can significantly influence material thinning and surface finish. The often-cited work of professor Masujiro Hayama (Yokohama National University), shows that low mandrel speed, small roller diameter and low-viscosity lubricants produce the best surface finish. Hayama proposed the following formula to determine roller diameter:
Dr = 0.1D + (120 ±60) mm
Where, Dr is the roller diameter in mm and D is the flat-blank diameter in mm.
Roller diameter should be less than the diameter of the spun component. Therefore, a large ± range in the formula ensures that the selected roller diameter is less than the component diameter. Large roller nose radii will produce more uniform thickness distribution and low surface roughness.
Mandrels are made from a range of materials such as cast iron, mild steel, tool steel, aluminum or magnesium. Larger parts produced from light-gauge, formable materials can be made with aluminum, wood or, potentially, plastic. Larger parts produced from more difficult materials can be constructed via tubing and steel or custom casting. Mandrels also function as supporting and rotating members in the metal spinning setup, meaning that they must be statically balanced. High speed calls for the dynamic balancing of large mandrels. In these cases, cored casting of steel or iron is preferred, in order to reduce the weight of the mandrel.
A blank-support attachment may be required in the early stages of spinning when high feed rates or thin materials are used. The blank, positioned between the support and the work roller to help control buckling and wrinkling, is similar to a blankholder in deep drawing.
Process Parameters
Key process parameters for spinning include roller feed rate, spindle speed, feed ratio, temperature and lubricants.Roller feed rate—the distance the roller travels into or along the workpiece with respect to time and measured in mm/sec. or mm/min.—affects formability and forming quality. A high feed rate causes the workpiece to conform more closely to the mandrel at the expense of surface finish. Too high of a feed rate causes buckling or wrinkling to occur. Reducing the feed rate improves surface finish, but at the expense of cycle time, thickness uniformity and dimensional accuracy.
Typically performed at room temperature, spinning processes may require heating above room temperature, especially when it comes to thick parts. At elevated temperatures the flow stress—the stress level required to cause or continue yielding—drops, making the blank easier to form. Increased formability proves useful when spinning machine capacity is insufficient to cold form the component or the alloy ductility is too low at room temperature.Lubricants, normally required during spinning, provide lubricity and cooling. Restricting the amount and location of the lubricant contributes to part quality and extended tool life. For example, an increase in blank temperature occurs during forming, reducing the flow stress in the blank. If wall-thickness control is important, this lessens part quality. On the other hand, an increase in ductility at elevated temperatures may be desirable when spinning materials with low ductility. In either case, lubricant decisions play a key role in achieving desired results.
Next month: advancements in metal spinning technology and tooling. MF
It is common to think of metal spinning and hydroforming as highly specialised and targeted metal-forming techniques. Consequently, many engineers need to know how useful these methods are.
Hydroforming and metal spinning are the most common industrial processes used to make many products, including gas cylinders, lighting gear, musical instruments, satellite dishes, etc. You may choose the most appropriate metal-forming technique for your needs by learning about the advantages of each procedure.
Hydroforming and metal spinning are the most effective and efficient techniques for producing high-quality, long-lasting metal components and parts.
Parts and components made with the hydroforming technique are robust and well-built, and there is almost little waste. One common method for making complicated components and parts out of flexible materials is the inexpensive and widely used hydroforming process.
The process of metal spinning, also known as spin forming, involves shaping metal discs using methods that are conceptually comparable to those used in the sculpture of clay pots. Metal spinning can be manually or automated using CNC lathes; the latter is more common for smaller production runs. Stainless steel dishes, gas cylinders, brass instruments, and bowls are some of the common metal components spun into production.
Spinning metal allows for the creation of any ductile metal, including:
Metal spinning is a cold forming, yet it can also be a hot forming technique, depending on the material.
Technicians can use a torch to hot-form a component when cold-forming isn't an option. With the item heated, it can be easily shaped or necked to smaller diameters with low effort and work hardening.
This is for all you machinists who have ever wondered what goes into making those pieces that look like bowls and top hats. For metal spinning to occur, a mandrel that has been machined to match the intended workpiece's dimensions and shape is used to gently push metal sheets over it.
The flow is improved wherever work hardening is an issue, such as in confined spaces, around corners, or during a "cold" operation. You might need a blowtorch to soften the metal.
Superalloys like titanium and Inconel and ductile metals like aluminium, copper, brass, carbon, and stainless steel are all good candidates for metal spinning.
For example, a bell-shaped mandrel would be mounted onto a lathe spindle to create a stainless-steel bell. The mandrel can be manufactured from metal, hard plastic, or wood for tasks requiring a higher production volume.
A thin disc, about 1/8 of an inch thick (or more or less, depending on the bell's size), is required to be slightly longer than the outer surface's maximum length. Some specialty businesses have suggested that materials with a thickness of 1 inch or more can be spun.
Aluminium, stainless, carbon, and high-performance alloys are just a few examples of ductile metals that can be created. Machine intricate curves, narrow grooves, and other complex features can be the machine with a single cycle.
Comparable in design to traditional turning centres, metal spinning lathes have indexable tool holders that permit the operator to swiftly and easily execute secondary turning operations and edge detailing without interrupting the process for setup.
Various forming procedures can be used for metal spinning depending on the building material and the desired output volume. For thinner gauge materials and low-to medium-volume applications, the hand-shaped metal might be best achieved by a trained operator delicately pulling a roller. This procedure is known as manual spinning. In situations when higher pressures are necessary, such as when working with harder metals or larger gauge materials, hydraulic-assisted spinning provides the advantages and versatility of manual spinning.
Including cutting-edge gadgets. With computer numerical control (CNC) controls, metal spinning becomes faster, more precise, and more consistent. Complex geometries with strict tolerance requirements can be produced quickly, accurately, and reliably in medium to high production numbers.
Modern computer-assisted machining (CAM) software is used to program this equipment. Additionally, operators can use a "teach" mode, where the computer records the movements of manually spinning the initial component. You can automate manufacturing a huge volume of components once the initial workpiece is made by using replay mode, which precisely replicates the actions of the hand-spinning operation.
One metal production method is sheet hydroforming, which involves using pre-shaped plates or dies and pressurised fluid to mould malleable metal into the desired components. Reduced wastage and guaranteed structurally durable parts and components result from hydroforming, a fast, efficient, and inexpensive metal-forming process.
Hydroforming is superior to conventional stamping when shaping complicated, asymmetrical, or intricate components. Hydroforming is the way to go if you need to shape carbon or stainless steel, copper, aluminium, bronze, or brass.
Among the many uses for hydroforming are the aerospace and defence industry, the commercial food industry, medical equipment, satellite communications, and many more.
Although the displacement mechanism differs in hydroforming and metal spinning, the two processes have similarities. For example, a blank marginally bigger than the final product is utilised as the foundation.
As long as the corners are rounded, hydroforming can create polygons and workpieces with irregular shapes; a round shape is not necessary. While metal spinning allows for forming a broad array of ductile metals, hydroforming suits smaller gauge materials and more intricate part geometries.
Copper, aluminium, carbon, nickel, stainless steel, and nearly all high-strength, high-temperature alloys can be hydroformed. This includes nearly all metals that can be cold-formed. Producing structurally solid components with diameters ranging from 1.0" to 30.0" and draw depths up to 12.0" is made possible by its expansive and versatile work envelope. The standard tolerances for aeroplanes, which are tight, are easily attained at ±.003".
A male dies and a draw ring, also known as a blank holder, make up the tooling used in sheet hydroforming. No fabrication is required because the hydroforming press's urethane rubber diaphragm serves as a universal female die.
Less complex tooling also allows for shorter lead times, and the process dynamics make it possible to modify the material thickness without changing the tool. Compared to traditional press tooling, hydroform tools often cost half as much, sometimes even less, than the latter.
Link to US Metal Spinning
A wide range of sectors utilise superior manufacturing techniques, including hydroforming and metal spinning, to create essential parts and components. You should consider the details of your application carefully before deciding which of these methods to use because each has its own set of benefits.
Producing components of exceptional quality and performance is another application of metal spinning. The metal spinning technique allows for the rapid creation of components, typically within a few weeks, greatly reducing the time it takes to have parts and components ready for use. The metal spinning technique usually allows the most adaptability and efficiency for making parts and components. Metal spinning works with various metals, including carbon steel and aluminium.
These techniques offer superior choices because of the relatively low tooling investment required for metal spinning and hydroforming compared to conventional deep drawing. Additionally, there is more leeway and setup times are reduced.
Hydroforming, in particular, is an area where these technologies may compete at bigger volumes. Many complicated, production-level components in the aerospace and automobile sectors employ it.
Metal spinning and sheet hydroforming are two manufacturing processes that have a lot of promise for prototypes and low to medium-volume production. This is a popular trend, especially for products with unique customisations, low demand, or a short life cycle due to changed consumer preferences.
Cheap, low-volume production also allows companies to break into untapped markets or carve out a unique niche in well-established ones. A corporation can test growth and expansion potential and product development plans in less-known markets by producing at a lower investment and volume, reducing risk and exposure.
Both metal spinning and hydroforming are extremely adaptable processes that find employment in various commercial, architectural, medical, transportation, and industrial settings. Both have the potential to enhance and add versatility to the production of a wide variety of components, and they can meet an almost endless diversity of design issues.
The car industry is one sector keen on using lighter components to achieve fuel reduction goals and cut CO2 emissions. Automotive manufacturers must use innovative production techniques and strong, lightweight materials like aluminium to reduce vehicle weight and meet the increasing demands for optimal fuel efficiency, safety, and environmental regulations. Engineers can specify stronger and more resistant to environmental exposures to spun metal or hydroformed components, which are lighter than machined or stamped counterparts.
Both of these production methods find application in the architectural sector for projects of varied sizes and degrees of complexity. Large quantities of cylindrical lighting components are available for commercial use. However, designers looking to add dramatic, one-of-a-kind lighting to a commercial project on a budget might benefit greatly from low-volume manufacture. Door knobs are just one example of an ordinary product that may have a personalised touch while still being functional and durable.
Spin and hydroforming are perfect for just-in-time delivery of a few units per order because technologically complicated equipment, such systems utilised in the medical business, is usually created in low volume numbers. The major benefits are avoiding the cost of long-term part inventories and making easy, low-cost design adjustments in response to technical developments.
There are several advantages of hydroforming over more traditional processes, such as stamping, including:
Hydroforming eliminates the need for further finishing processes and forms structurally sound, flawless components in approximately 20 seconds with a tolerance of +/- 0.003 inches.
Hydroforming is the way to go for parts with complicated or odd shapes.
Hydroforming is economical for small, medium, and big batches. The great adaptability of hydroforming to design modifications makes it a great material for prototyping.
When compared to metal stamping, hydroforming leaves almost no scrap.
The benefits of metal spinning for a flexible and efficient process include:
Metal spinning may be easily adjusted to meet the changing needs of product designs, providing maximum flexibility at all times.
Components that demand exceptional strength and aesthetics might benefit from metal spinning, which creates seamless, long-lasting pieces devoid of seams or welds.
Metal spinning tools are usually 10% more expensive than equipment used in other forms of forming, such as stamping, casting, and forging.
Significantly reduced turnaround times are made possible by the metal spinning process. We can have the tooling and spun components ready in weeks.
Numerous sectors make use of metal spinning and hydroforming methods, such as:
components of aircraft, satellites
surface cookware, well-seasoned cookware
lighting components,
energy equipment for solar, steam, and wind power, in addition to fuel cells
Thermostats, HVAC, filters, and pressure vessels; OEM partner
medical imaging facilities, research tools
drilling for oil, pipelines
parts for hot rods, rims for wheels, and housings made of steel
Metal spinning and hydroforming are two specialised ways to shape metal that are used in many fields, such as to make gas tanks, lighting equipment, musical instruments, and satellite dishes. They work well and quickly to make high-quality metal parts and components that last a long time. Metal spinning is the process of shaping metal plates in ways that are similar to making clay pot sculptures. It can be done by hand or automatically with CNC lathes. It can be used to make any metal that can be bent, like aluminium, stainless steel, alloy steel, gold brass, and steel titanium Hastelloy.
Metal spinning can be done on superalloys like titanium and Inconel or ductile metals like aluminium, copper, brass, carbon steel, and stainless steel using a mandrel that has been made to fit the size and shape of the workpiece that will be spun. Depending on the building material and the amount that is wanted, different forming methods can be used. For smaller gauge materials and low to medium-volume jobs, manual spinning works best. Hydraulic-assisted spinning, on the other hand, has all the benefits and flexibility of manual spinning.
Hydroforming is a quick, easy, and cheap way to shape metal that cuts down on waste and makes sure that parts and pieces will last. It works better than regular stamping when shaping parts that are difficult, asymmetrical, or intricate. Hydroforming works well with thinner materials and parts with complicated shapes, which makes it a great choice for many businesses.
Hydroforming and metal spinning are two ways that parts and pieces are made and used in many different industries. With hydroforming, you can make physically solid parts with diameters from 1.0" to 30.0" and draw depths up to 12.0". Compared to standard deep drawing, it requires fewer tools, gives you more freedom, and takes less time to set up.
For example, metal spinning lets parts be made quickly—within a few weeks—which cuts down on the time it takes to get them ready to use. It can be used with many metals, such as aluminium and carbon steel. Both ways are good because they can make things quickly and efficiently, give you more design options, use cheaper tools, and cut down on wait times.
Hydroforming is very popular in the aerospace and auto industries because it can compete at higher volumes and meet the growing needs for safety, fuel economy, and environmental regulations. It can also be used for just-in-time delivery of a few units per order since high-tech items are usually only made in small quantities.
Hydroforming is better than standard methods in many ways, such as speed, efficiency, complexity, cost-effectiveness, and long-term use. Metal spinning gives you more design options, high-quality, seamless pieces, cheaper tools, and shorter wait times.
These methods are used in many fields, including architecture, commercial kitchenware and tools for food preparation, energy, industry, medicine, oil and agriculture, and vehicle parts.
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