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OUTLINE
INTRODUCTION.
HISTORY.
CLASSIFICATION OF METAL SPINNING TECHNIQUES.
METAL SPINNING PROCESS.
MECHANICS.
TOOLS AND EQUIPMENTS.
COMPARISON WITH OTHER FORMING PROCESSES.
MERITS.
DE-MERITS.
APPLICATIONS.
CONCLUSION.
INTRODUCTION
Let us try
and identify
the key
components
here
INTRODUCTION
HOW DO WE DEFINE THIS?
WHERE DO WE USE
THIS?
to manufacture low cost, rapid
prototypes in metals.
bell shaped curves are ideal for
spinning as metals can deform
smoothly around them
easy to create concentric ribs to
strengthen parts
Almost all metal in sheet form can
be spun
Specially used when the product
requires mirror sheen
EVERYDAY EXAMPLES
CRITICAL QUESTIONS
1)
2)
3)
HISTORY
CHALICE
Metal Spinning
CLASSIFICATION OF METAL
SPINNING TECHNIQUES
Manual
(Conventional)
Spinning
Power Spinning
Tube Spinning
PROCESS OF SPINNING
Let us look
at a video
of metal
spinning
process
This step involves the laying down of the material onto the mandrel.
It is accomplished with short inside to outside moves.
Material gets easier to form as the part is closer to completion
Step 2 : Trimming
Parts having been spun are trimmed at the end to blunt sharp edges and also to bring the
component to the desired length.
Step 3 :
Finishing
Finishing is done at very high RPMs (1200+) so that a minimum of force need be applied
and very smooth strokes can be used.
The flat side of Duckbill spinning tool is used for straight surfaces and rounded side for
curves and radii.
The sine law relates the wall thickness of the starting bla nk, t 1 ,
and the wall thickness of the fi nished product, t 2 , as t 2 = t 1
(sin ), where is the semi-apex angle of the cone.
T h e m a n d re l d i a m e t e r i s 7 . 5 i n c h
( 1 88 m m ) .
T h e t h i c k n e s s o f t h e p re - f o rm i s
0. 5 i n c h .
T h e i n c l u d e d s e m i - a p ex a n g l e o f
t h e c o n e i s 3 0 d e g re e .
Wa l l t h i c k n e s s o f fi n i s h e d
component is 0.25 inch.
T h e s e m i - a p ex a n g l e o f t h e c o n e
i s l e s s t h a n 1 5 d e g re e .
T h e t h i c k n e s s o f t h e fi n i s h e d
c o m p o n e n t i s re d u c e d
s u c ce s s i v e l y i n a c c o rd a n c e w i t h
t h e s i n e l a w , t o 0 . 1 25 i n c h .
Original blank diameter is
re t a i n e d a t t h e b i g e n d o f t h e
cone.
MANDREL
T h e m a n d re l o r b u c k i s t h e f o rm o v e r w h i c h t h e s h e e t m e t a l b l a n k i s f o rm e d .
M o re c o m p l i c a t e d t h e f o rm o f t h e co m p o n e n t , t h e g re a t e r t h e n e e d f o r c a re
i n m a c h i n i n g t h e m a n d re l .
C a n b e m a c h i n e d f ro m a v a r i e t y o f m a t e r i a l s , w o o d b e i n g t h e ch e a p e s t .
M a n d re l s c a n a l s o b e m a d e o f m i l d s t e e l o r a l u m i n i u m , w h e n c l o s e
t o l e r a n c e s a re re q u i re d .
I t i s i m p o r t a n t t o d e s i g n t h e m a n d re l w i t h a t l e a s t a 1 d e g re e d r a ft a n g l e s o
t h a t t h e p a r t c a n b e re m o v e d f ro m t h e m a n d re l a ft e r s p i n n i n g .
TOOLS
Wi d e v a r i e t y o f t o o l p ro fi l e s c a n b e i m p l e m e n t e d f o r s p i n n i n g t h e
m a t e r i a l i n t o d i ff e re n t s h a p e s .
To o l s a re p ro v i d e d w i t h l o n g h a n d l e s t o p ro v i d e a m p l e l e v e r a g e t o w o r k
t h e m a t e r i a l d o w n t h e m a n d re l .
To o l s c a n b e u p t o 3 f e e t l o n g w i t h a 1 i n ch d i a m e t e r s t e e l ro d f o rg e d
i n t o t h e p re f e rre d t o o l t i p .
S p i n n i n g s h o p s m a ke u s e o f t o o l s w i t h ro l l e r s m o u n t e d o n t h e l o n g
handle.
T h e p r i m a r y t o o l s a re t h e S h e e p s n o s e u s e d f o r m o s t o f t h e f o rm i n g
a n d t h e D u c k s b i l l u s e d f o r fi n i s h i n g o p e r a t i o n .
Ducks bill
Sheeps nose
Roller-ended tool
LUBRICANTS
Lu b r i c a n t s a re e s s e n t i a l i n a l l m e t a l s p i n n i n g o p e r a t i o n s , re g a rd l e s s o f
t h e p re f o rm s h a p e o r c o m p o s i t i o n o r t h e t y p e o f m e t a l s p i n n i n g t o o l s
t h a t a re b e i n g u s e d .
Fa c i l i t a t e s e a s y r e m o v a l o f t h e p a r t f ro m t h e m a n d re l a n d a l s o h e l p
i m p r o v e s u r f a c e fi n i s h o f fi n i s h e d c o m p o n e n t .
Pa r t s a re l u b r i c a t e d b o t h b e f o r e a n d d u r i n g t h e s p i n n i n g o p e r a t i o n .
C o m m o n l y u s e d l u b r i c a n t s i n cl u d e w a x , t a l l o w s , s o a p s a n d g re a s e .
I n s e l e c t i o n o f t h e m o s t s u i t a b l e l u b r i c a n t , t h e e a s e o f re m o v a l o f t h e
s a m e a ft e r t h e f o rm i n g p ro c e s s h a s t o b e c o n s i d e re d .
Cup Grease
Tallow
hematic diagrams of a vertical arrangement employed for spinning of large diameter cone
SPINNING MACHINES
MERITS
Pro v i d e s n a t u r a l m e t a l l u rg i c a l b e n e fi t s , w i t h a re fi n e d a n d s t re n g t h e n e d
g r a i n s t r u c t u re .
C o l d w o r k i n g o f t h e m e t a l a l s o i n cre a s e s t e n s i l e p ro p e r t i e s a p p re c i a b l y.
U n l i ke a c a s t i n g , a s p u n p a r t w i l l n o t b e d i s ca rd e d b y a h i d d e n b l o w h o l e
or inclusion.
A s p u n s h e l l c o u l d b e m a d e i n h a l v e s a n d w e l d e d t o f o rm a s i n g l e u n i t
w i t h o u t c o m p l ex , ex p e n s i v e t o o l i n g .
T h e t o o l i n g c o s t s a n d c a p i t a l i n v e s t m e n t s a re re l a t i v e l y s m a l l .
The setup time is less.
D e s i g n c h a n g e s i n t h e w o r k p i e c e c a n b e a c c o m m o d a t e d a t re l a t i v e l y l o w
costs.
C a n b e e a s i l y a u t o m a t e d a n d i s a n e ff e c t i v e p ro d u c t i o n m e t h o d f o r
p ro t o t y p e s a s w e l l a s h i g h p ro d u c t i o n r u n s .
S i n c e t h e re i s n o re m o v a l o f m e t a l b y f o rm a t i o n o f ch i p s , t h e re i s n o
m a t e r i a l w a s t a g e a n d t h e p ro c e s s i s e c o n o m i c a l .
DE-MERITS
APPLICATIONS
The following are examples of products
that can be manufactured by metal
spinning:
Vases, baskets, basins and bowls.
Bottoms for tanks, hoppers and kettles.
Housings for blowers, fans, fi lters and
fl y-wheels.
Ladles, nozzles, orifi ces and tank
outlets.
Cones, covers and cups.
Funnels, cylinders, domes and drums.
Rings, hemispheres and shells.
Vents, venturis and fan wheels.
CONCLUSIONS
Metal spinning techniques and mechanics have been
presented.
Equipment for spinning is based on lathe technology.
Wide range of products can be obtained using this
technique.
Metal Spinning is competitive with other forming
processes such as pressing and deep drawing.
It is an economical technique to produce both simple
and complicated parts for single application, lowvolume production as well as mass productions.
Process technology, equipment and tooling for
spinning have been discussed.
THANK
YOU