A wide variety of businesses make use of metal spinning. It's a more cost-effective option than starting from scratch with machining, and it produces a finished product that doesn't need any further polishing to be usable.
While stainless steel and aluminium are the most popular metals for metal-spun components, titanium, magnesium, copper, and many more can be formed this way!
Table of Contents
What Is Metal Spinning?
The asymmetrical metalworking technique known as metal spinning involves fitting a flat or circular piece of metal into a hand lathe or computer numerical control (CNC) lathe. A pressure pad keeps the metal disc in place while it is spun at the right speed.
Using a "chuck" or mandrel and a variety of rollers or tools, the metal is gradually formed by applying a localised force, either by hand or by machine. It is possible to achieve a precise form with complex spinnings using numerous chucks. Hardened metals or wood are the materials used to make chucks.
Exploring the Use of Metal Spinning in Major Industries
Air Movement / HVAC
One typical use for metal spinning is to move air. Metal spinning is a great process for making AC flanges, duct covers, and outlets.
Ductwork air seals are made with flanges. This ensures a solid bond between the ducting and the system's cooled or heated equipment. Hoses and pipes are frequently connected to tanks and other containers that use flanges to store pressurised liquids, gases, or steam.
Installing HVAC systems in homes or buildings necessitates using duct casings to shield the system's internal components from the elements and potential damage.
Metal spinning makes HVAC flanges easy to install and doesn't wear out other system components. Because repairs are only sometimes needed with plastic components, this procedure lowers the maintenance expenses of HVAC equipment over time.
Filtration
Filters for swimming pools, water treatment plants, and other applications are also made by spinning metal. Metal-spun filters may remove dangerous impurities from high-pressure streams without compromising their strength.
Filters made from spun metal have many potential uses, one of which is in water purification systems. Filters play a crucial role in numerous industrial processes and systems to guarantee that only pure goods are sent out of a facility. Filters also help prevent workers' exposure to potentially dangerous substances through consumption or inhalation.
Oil & Gas
Metals are essential to producing all the tools in the oil and gas industry's massive exploration and production operations. Although carbon steel, aluminium, and stainless steel are the most used metals, they all present different difficulties.
- Problems with corrosion resistance can arise in oil refineries and other places that handle chemicals, whether through storage, processing, or pipeline transportation.
- Fire Safety in the Oil and Gas Industry: Offshore drilling platforms, petrochemical plants, chemical plants, and refineries are all industrial process facilities that must adhere to strict fire safety regulations. Powder or paint finish coatings, such as PTFE or other fluoropolymer resin systems, can make metal spun components stronger, more corrosion resistant, and capable of withstanding high temperatures, making them a viable alternative to conventionally welded structures.
Aerospace
Parts for aeroplanes, rockets, spaceships, and missiles are made using metal spinning in the aerospace sector.
Spinning metal creates complex structures that regular production processes cannot.
Due to their strength and lightweight nature, aluminium alloys are commonly used in aeronautical parts.
Architectural
Architectural features like railings and handrails make use of metal spinning.
Other common uses for metal spinning include fences, gates, grilles, and window guards.
Your neighbourhood courthouse or police station might even have metal-spun security gates!
Automotive
Metal spinning has several potential applications, including the automotive industry. Engine, gearbox, brake, and other components are among those that are metal spun. The automotive sector makes use of metal-spun components such as these:
- An aluminium alloy gas tank is a metal spun component.
- Another metal-spun component composed of aluminium alloy is the fuel tank. For automobiles that are getting on in years or have rust issues from lack of care, it's a common replacement.
- Wheel rims—the wheel rim is just one component of the wheel. The tyre lies on the wheel's outer edge, as illustrated below.
Food Service
One important market for metal spinning is the food service industry. Metal spinning has many uses in this field:
- Cutlery and platters for serving
- Implements and implements for food processing
- Tools and equipment for food packaging
- Equipment for preparing food
The Three Main Methods for Metal Spinning
Metal spinning primarily consists of three steps. Several factors define the various methods, including material deformation, surface roller and blank positioning, mandrel use or absence, and blank temperature.
Conventional Spinning
Metal Spinning includes the technique of conventional spinning, which is also called compression forming. When manufacturers use this approach, the blank's wall thickness stays relatively stable during spinning. The spinning part's finished wall thickness is the same as its blank thickness.
Depending on their size, material, and quality specifications, a single roller pass may be sufficient to spin some components.
How many rollers pass, and in what direction do they define the wall thickness in multi-pass conventional spinning? The material is thinned out as the surface roller travels ahead; the metal is shifted in opposing directions as it travels rearward, guaranteeing a constant wall thickness and less spring-back.
To make the spinning portion more precise and attractive, a technique called "Planishing" is applied. Planishing is a finishing pass with the surface roller to smooth out the waves that have formed throughout the spinning process. Reducing feed and speed applies a high radial force, which improves surface smoothness in the last roller pass.
The most common shapes spun using conventional methods include domes, cylinders, cones, and combinations of these three. Even though the spun pieces' diameter will always be decreased, the wall thickness will stay the same.
Conventional spinning can be done on manual or CNC metal spinning lathes and can be done with or without a mandrel. This Metal Spinning method can also make two sub-processes: outside spinning (necking) and interior spinning (expanding).
Flow Forming
As for the second technique, flow forming—tube spinning—is closely related to shear forming and spinning. Flow forming is quite similar to traditional spinning, except that the blank's wall thickness is lowered. This is done purposefully since the wall thickness will be thinned out as the necessary part is extended.
Despite having many similarities with traditional spinning, the flow-forming method necessitates supplementary tools for execution.
The operation involves clamping a hollow, axially symmetrical component between the tailstock and mandrel. The metal of the hollow component presses against the mandrel as two or even three rollers, rather than a single roller, exert pressure simultaneously.
Traditional spinning often makes use of tubular blanks rather than sheet metal discs. These might take the shape of a cup or sleeve. In addition to having low flow stress, the materials utilised in this method possess a high tensile-to-yield-strength ratio. It is common practice to spin or deep-draw the blanks to create them.
Hydraulic cylinders and other cylindrical hollow components can be attractively manufactured using flow-forming. This is because, unlike other materials, it can be cold-worked to improve hardness, and with relatively simple tool designs and inexpensive tooling costs, it delivers significantly higher surface finishes.
Shear Spinning
The third way to spin metal is shear spinning, which uses a conical mandrel to shape sheet metal. A standard metal spinning lathe is commonly used for this.
The angle between the part's wall and the axis of rotation determines the purposeful reduction of the blank's wall thickness, similar to flow forming.
This metal spinning technique is distinct from others since the roller only needs to make one pass over the material before it stretches over the mandrel. The final part's outer diameter is equalised with the original blank diameter by applying a compressive force while the roller rolls.
Because the ' shear angle' of the vertical walls is 0 degrees, shear spinning, unlike normal spinning, does not result in cylindrical structures. This phenomenon is known as shear spinning.
Advantages and Uses of Metal Spinning
Metal spinning is a machining method that involves turning a metal rod or disc at high speed on a horizontal or vertical lathe until the product is axially symmetrical. One major benefit of spinning over other forming methods is making things out of a single piece of material with relatively inexpensive equipment. Greater internal and exterior stresses can be withstood by pieces that do not have seams.
Spun metal is commonly used in architectural and ornamental components. Machines, gas cylinders, cookware, and brass instruments utilise spun metal components, which can be manufactured from various materials. The three most popular materials for spinning are as follows.
Steel
Cost, the finished item's intended shape, and intended use are the three most critical considerations when selecting a material for spun parts. Steel is often less expensive than other metals. However, fuel prices, worldwide supply and demand, and raw material prices can dramatically affect commodities prices.
Steel, being tougher than aluminium, is an incredibly long-lasting material. Because of its resilience, it can withstand high pressures and temperatures without distorting or bending. Steel, moreover, is an extremely thick substance. Compared to aluminium, its density is 2.5 times higher. This makes sure that the steel spun components won't be readily damaged.
Aluminum
Aluminium is more pliable and elastic than steel, but it is also more expensive. Consequently, it can be utilised to fashion forms with more complex and profound characteristics, which, when spun using steel, would inevitably fracture or tear.
Aluminium doesn't need any surface treatment after spinning because it is naturally resistant to corrosion and doesn't rust or malleable. Scratches and surface wear that could lead to corrosion are not an issue because coating or painting is unnecessary. Because of this, aluminium is the material of choice in damp or rough settings.
Copper
Among the most popular metals spun, copper ranks high alongside steel and aluminium. Aesthetically pleasing, non-magnetic, and very adaptable. Compared to steel and aluminium, copper is usually the more costly metal.
Its most notable features are its antibacterial properties, excellent ductility/workability, recyclability, corrosion resistance, and outstanding thermal and electrical conductivity. Curiously, when subjected to work hardening, its tensile strength increases by half. Copper is also an easy-to-work-with metal because of its softness.
Copper-spun parts benefit from lighting, plumbing, medical devices, roofing, and even jewellery.
Other Metals
In addition to the more common metals like steel, aluminium, and copper, Helander also makes spinning parts from Hastelloy, Inconel, bronze, titanium, and brass. Each of these metals has its own set of advantages and disadvantages.
The smooth design, inexpensive tooling, and minimal material waste make metal spinning an excellent option for symmetrical components. Spun components can be made from many different metals; the one that's best for your project will depend on factors including budget, part shape, and operating conditions.
Although aluminium allows for more intricate part forms and has better corrosion resistance, steel is a more affordable material with good strength and permanence. Copper is similar to aluminium in numerous ways, although the price is usually higher. Because of this, copper is a good choice when the value of its aesthetic qualities is more important than its expensive price.
Conclusion
Metal spinning is a cheap and flexible way to work with metal that is used in many fields, such as food service, air movement, filtering, oil and gas, and aircraft. A pressing pad holds the metal disc in place while a flat or round piece of metal is fitted into a hand lathe or CNC lathe. Localised force is applied to the metal over time, either by hand or by machine.
Spinning metal is often used in moving air, HVAC, filtering, oil and gas, aerospace, architecture, food service, and the automobile industry. To move air, you need to make AC flanges, duct covers, and ports. Filtering takes away harmful impurities from high-pressure streams without weakening them. In oil refineries and other chemical companies, metal spinning is also a very important part of fire safety.
Metal spinning is used in the aircraft industry to make complex structures that can't be made any other way, like fuel and gas tanks made of aluminium alloy. Metal spinning is often used to make architectural parts like stairs, railings, fences, gates, grilles, and window guards.
Metal spinning is used in the car industry to make parts for the engine, gearbox, brakes, and other parts, like fuel tanks and gas tanks made of aluminium alloy. Metal spinning is used to make cutlery, platters, tools and equipment for processing food, tools and equipment for packaging food, and tools and equipment for making food.
There are three main ways to spin metal: conventional spinning, which includes changing the shape of the material, where the surface roller and blank are placed, whether or not a mandrel is used, and the temperature of the blank. You can use a manual or CNC metal spinning lathe to do conventional spinning, and you don't need a frame to do it.
Flow making is a method that is similar to traditional spinning, but the wall thickness of the blank is purposely lowered. A hollow, horizontally symmetrical part is clamped between the tailstock and the mandrel, and rollers apply pressure at the same time. This method is often used for hollow cylinders because it can be cold-worked to make them harder and give them better surface finishes.
A third way to form sheet metal is by shear spinning, which uses a cone-shaped mandrel. The angle between the part's wall and the axis of rotation decides how much the blank's wall is purposely thinned out. Shear spinning doesn't make objects that are shaped like cylinders.
A metal rod or disc is turned very quickly on a horizontal or vertical machine in the metal spinning method until the finished product is symmetrical along its length. It is often used in machines, gas tanks, cookware, and brass instruments, as well as in architectural and decorative parts.
Steel, aluminium, and copper are the three most common things used for turning. Most of the time, steel is cheaper than aluminium. However, product prices can be affected by things like the price of fuel, supply and demand around the world, and the price of raw materials.
Aluminium is more flexible and springy than steel, but it costs more. This makes it good for making complicated shapes. Many people also like copper because it is hygienic, flexible, can be recycled, doesn't rust, and is a great conductor of heat and electricity.
Content Summary
- Metal spinning transforms metal into axisymmetrical parts, offering cost-effectiveness and a polished finish.
- Utilising stainless steel and aluminium, metal spinning also shapes titanium, magnesium, copper, and more.
- The process fits metal discs into lathes, either manually or via CNC, to mould them into desired shapes.
- Metal spinning generates complex shapes while maintaining the initial thickness of the metal sheet or disc.
- Metal-spun products serve various industries, from decorative items to practical components.
- The technique is ideal for prototyping, custom fabrications, and medium to large-batch productions.
- Metal spinning involves conventional spinning, shear spinning, hot spinning, and tube spinning.
- Conventional spinning maintains material thickness, altering the workpiece's diameter and depth.
- Shear spinning thins the material, enhances mechanical properties, and requires robust tooling design.
- Hot spinning and heating the workpiece for shaping improve grain structure but risk oxidation.
- Tube spinning extends and thins hollow cylindrical tubes, necessitating complex tooling design.
- Adjustments in spinning include feeds, pressure, roller shape, RPMs, and material thickness.
- Metal spinning supports necking, expanding, planishing, and cutting to achieve precise forms.
- Various metals are compatible with metal spinning, including aluminium, steel, brass, bronze, Hastelloy, and titanium.
- Aluminium's abundance and corrosion resistance make it widely used for spinning, offering a lightweight alternative to steel.
- Steel, including stainless and carbon steel, is chosen for its durability and cost-effectiveness.
- Brass, known for its electrical conductivity and decorative appeal, is easily spun into various items.
- Bronze offers greater strength and corrosion resistance, which is ideal for durable and decorative uses.
- Hastelloy's chemical and corrosion resistance suits harsh environments like chemical plants.
- Titanium, though costly and less common in spinning, provides a high strength-to-weight ratio.
- Metal spinning benefits include versatility, cost-efficiency, efficient material usage, consistency, and precision.
- The process is suitable for rapid prototyping, design flexibility, and producing durable, strong parts.
- Metal spinning applications span industries like air movement/HVAC, filtration, oil & gas, aerospace, architecture, automotive, and food service.
- In HVAC, metal spinning creates flanges, duct casings, and outlets, reducing maintenance costs.
- Filtration uses spun metal to remove impurities in high-pressure streams, which is crucial in water purification and industrial processes.
- The oil & gas industry utilises spun metal for corrosion-resistant components, benefiting refineries and chemical handling.
- Aerospace employs metal spinning for parts in aircraft, rockets, and missiles, utilising aluminium alloys for strength and lightweight.
- Architectural features, including railings and handrails, benefit from the decorative and functional aspects of spun metal.
- The automotive sector uses spun metal for engine components, fuel tanks, and wheel rims, leveraging steel's durability.
- The food service industry relies on spun metal for cutlery, cooking equipment, and food processing implements.
- Metal spinning techniques include conventional spinning for maintaining wall thickness, shear spinning for reducing thickness, and flow forming for tube shaping.
- Conventional spinning is versatile, allowing for the creation of domes, cylinders, and cones without changing the material's thickness.
- Shear spinning specialises in conical shapes, reducing wall thickness while maintaining the outer diameter.
- Flow forming, or tube spinning, focuses on extending hollow components enhancing surface finishes and material hardness.
- Steel offers affordability and durability, making it a practical choice for various applications.
- Aluminium's malleability and corrosion resistance make it ideal for intricate designs and environments prone to moisture.
- Copper's antibacterial properties and excellent conductivity suit applications in lighting, plumbing, and medical devices.
- Brass and bronze provide decorative appeal and added strength, respectively, for ornamental and structural components.
- Hastelloy and titanium offer exceptional resistance qualities, suitable for demanding industrial and aerospace applications.
- Metal spinning supports design flexibility, allowing engineers to realise innovative and complex shapes.
- The process's cost-effectiveness and rapid prototyping capabilities benefit businesses by reducing manufacturing expenses and lead times.
- Durability and strength are key advantages, making spun metal parts suitable for high-performance uses.
- Metal spinning's environmental benefits include minimal waste production and the potential use of recycled materials.
- The technique's historical roots enrich its modern applications, blending craftsmanship with contemporary manufacturing needs.
- Advances in metal spinning continue to expand its capabilities, improving efficiency and broadening its application range.
- Collaboration between designers and metal spinners enhances product quality and innovation.
- Metal spinning's versatility and affordability make it a valuable manufacturing method across industries.
- The seamless construction of spun parts enhances their functionality and aesthetic quality.
- Understanding the nuances of metal spinning can lead to improved product designs and manufacturing outcomes.
- Metal spinning remains a dynamic and evolving field, contributing to advancements in product design and manufacturing.
Frequently Asked Questions
Metal spinning plays a crucial role in the HVAC sector by producing components like air vents, ductwork, diffusers, and heat exchanger parts, offering durability and precision in fabrication.
Metal spinning allows manufacturers to create custom-designed components quickly, cost-effectively, and with minimal material waste, making it a preferred method for producing prototypes and small to medium-sized batches.
Metal spinning offers greater versatility than many other metal-forming processes since it can produce shapes ranging from simple cylinders to intricate domes and cones without requiring extensive tooling changes.
Metal spinning finds niche applications in medical devices, scientific equipment, marine technology, and renewable energy systems, where unique shapes and materials are required for specific purposes.
Metal spinning enables innovation and product development by allowing engineers and designers to experiment with different shapes, materials, and geometries, creating lightweight, durable, and aesthetically pleasing components across diverse industrial sectors.