Metal spinning is an impressive production method refined and polished throughout the years. From precision components to works of ornamental art, this approach has subtly benefited several sectors. Immerse yourself in the captivating realm of metal spinning as we explore the process and its numerous advantages in this article.
Table of Contents
The Art Of Metal Spinning
Metal spinning, often called "spin turning" or "spin forming", is a manufacturing method that manipulates flat metal discs or sheets into certain shapes by rapidly rotating them. Complex technology, expert hands, and pinpoint accuracy are all needed for this complicated art. Spinners are skilled craftspeople who employ this technology to make various things, from basic cylinder shapes to intricately designed sculptures.
Process Overview
Material Selection
Picking out the metal to spin begins with thorough consideration of the material. Depending on the intended usage and result, a wide range of metals can be utilised, including copper, stainless steel, aluminium, and even precious metals like silver.
Blank Preparation
A flat disc of metal, called a blank, is shaped and cut to size. After that, the blank is fastened to a lathe that is turning.
Spinning Lathe Setup
An essential tool for this operation is the spinning lathe, which spins the blank rapidly. Based on the material and the intended shape, this rotation can approach hundreds of revolutions per minute.
The Spinning Begins
Professional spinning equipment, such as "chucks" and "mandrels," moulds the metal. With these tools, the spinner may gradually mould the metal by applying pressure while the blank spins. The process requires a careful eye because even a small change might impact the end product.
Finishing Touches
To fix any flaws, the metal is thoroughly examined after the required shape has been reached. Polishing or coating the spun metal's surface is another option for improving its look and functionality.
Metal Spinning Speeds
The dimensions (diameter, thickness, and workability) of the spun metal sheet determine the rotational speeds that can be achieved. For heavier or larger blanks, a slower speed is required. Typical peripheral spinning speeds range from 600 to 1800 pm for a blank diameter of 7.5 to 22.5 cm, 1200 to 2400 pm for a diameter of 22.5 to 45 cm, and 1650 to 3000 pm for a diameter of 45 to 125 cm.
The Advantages Of Metal Spinning
We may now examine the many advantages of metal spinning because we have discovered its complex process:
Cost-Effective Production
Metal spinning can be a cost-effective production method when making components in small to medium batches. There is a decrease in initial expenses due to the process requiring minimum tools and setup.
Because tools can be made according to the expected lifespan of their intended work, tooling costs are kept low, for a one-time request, we may make the tool from wood. The tool would be made from hardened D2 steel for long-life orders. Although this is more expensive than a wooden tool, buying it all at once can save your firm money. Alternatively, you might spend a lot of money on wooden tools.
As an added convenience, we can keep your tools for up to a year after your last order. With this, you may save even more time and money on your next order for the long haul.
Due to the simplicity of the tooling, metal sinning is significantly more cost-effective than traditional casting and stamping. You can save even more money using Excel's fabrication processes that work with Metal Spinning, giving you a one-stop shop for all your metal spinning manufacturing needs.
Design Flexibility
Metal spinning's adaptability is mind-boggling. In contrast to other methods, it facilitates the construction of complicated structures, such as hemispheres, irregular geometries, and cones.
Metal Spinning is the more economical choice since it is easy to make changes to the design—which relates to the first benefit. Businesses frequently request component changes and reductions in size throughout the product development stage. Reducing the tool size in-house saves time and money because it eliminates the need to start anew.
As a result, Metal Spinning is a great material to use for prototypes.
Material Efficiency
Metal spinning produces very little waste because it just takes one metal blank to make the finished product. This efficiency aids both material prices and environmental initiatives.
Rapid Prototyping
Metal spinning is a great option for sectors that need to test and prototype products quickly. Compared to more conventional production techniques, it provides a reduced lead time.
Superior Strength And Durability
Because of the work-hardening effect during spinning, spun metal components are often much stronger and last longer than other metal components. Because of this, they can be used in situations where dependability is paramount.
Aesthetic Appeal
The aesthetic value of metal spinning is high, adding to its value beyond its practical benefits. Decorated pieces, lighting fixtures, and creative sculptures decorate residential and commercial environments, all crafted by artisans and designers using this approach.
Improved Material Properties
Metal spinning, which involves passing the material repeatedly, has additional benefits. This is because it causes the materials to harden, allowing you to utilise lighter, less expensive materials for your components (though this will depend on their intended purpose).
Short Lead Times
Quick, efficient, and cost-effective, the Metal Spinning process is hard to beat. Made in a couple of days, small to medium batch sizes are possible because of the quick lead times. We usually recommend at least three weeks when dealing with thousands of units in a batch. Because Metal Spinning requires nothing like in-house tooling, your supply chain will run smoothly, thanks to this.
Economically Efficient
Metal spinning is the most environmentally friendly method of metal formation since it uses less material than other processes like forging, stamping, casting, etc., and produces less waste. The full sheet metal disc is utilised in the metal spinning process, which explains why. Metal chips are a byproduct of the cutting, spinning, and deburring processes that create metal discs from sheet metal. Nevertheless, the remaining metal pieces are subsequently recycled and repurposed.
Inexpensive Tooling
Traditional dies for casting or stamping are costly. The spinning tooling process is easy and cheap. Compared to other forming processes, this one usually requires less equipment, just a mandrel, a tool stop, and a lever or chest tool. Occasionally, we can rotate around. To guarantee a perfect first-time finish, we create and construct our tooling. The pressing division of our company is an asset to the spinning division.
Higher Strength (Improved Metallurgy)
Tools used repeatedly to work on a product increase its hardness and tensile strength compared to those drawn. The use of lighter metal is possible in certain situations.
Tailor-Made Tooling
It is possible to keep tooling costs in sync with the expected lifespan of the parts. Use soft tools if it's a one-time task. Hardened tooling is more costly and is needed for repetitive activities or long runs.
Ease Of Design Changes
These can be manufactured if the smaller tool is more affordable than other tooling options. Variables can be honed and improved. We can make changes to the parts without having to start from scratch. With its low start-up costs, metal spinning is the perfect solution for sheet metal prototyping, which is often necessary in new product development due to the rapid changes.
Short Turnaround
Turnaround time can often exceed a few days. We make our tooling in-house, and it's cheap. In a little over 72 hours, metal spinning can be your solution for small to medium-quality needs. For instance, small production runs can be kept more affordable using hand metal spinning because of the faster setup time. In addition, it is done by skilled workers, which enhances dimensional stability and provides for more precise control over wall thickness.
Combination Spinning / Draw
On numerous occasions, we move in a deep draw. The approaches work best when used in tandem.
Competitive Pricing
Products are reasonable but more affordable than other manufacturing methods. Our procedures frequently produce cheaper, higher-quality products than stamping, deep drawing, and die casting.
Prototypes
Our ability to quickly and reliably deliver is at our fingertips.
Wide Range Of Part Sizes
Metal spinning provides an enormous size range, from 1" to 5'.
First Article
Before we start making the product, we can spin it in one or two portions so you can see how it looks.
Minimal Scrap
When working with metal, the safest method is to spin it.
Secondary Operations
Everything is handled internally.
Limitations Of Spinning
More Time Required:
More time is spent spinning than painting while making a cup.
More Skill Required:
More skill is required because the tool is forced on the metal blank by hand during spinning.
Not Suitable For Large-Scale Production:
Because it takes more time, the spinning method could be better for mass production.
Design Considerations In Metal Spinning
Parts designed for conventional spinning should consider the material's workability, bend radii, thickness, depth of spinning, diameter, and steps in diameter. The conical shape is the most simplified to make.
Producing hemispherical shapes, particularly in full-depth components, is a little trickier. The easiest forms to work with are those that are cylindrical or cup-shaped. Intermediate annealing is required at three or four stages of the spinning operation for deep-spun components.
A two-piece, sectional, or off-centre roll chuck can manufacture intricate forms or 'closed' components that would be impossible to spin manually on a standard open chuck. After the work is spun into a simple cylindrical cup shape, it is placed on this machine to undergo the last spinning process of bulging. To do a necking operation, install a spinning roll outside and an offset tail spindle inside.
The stock area grows marginally as a result of thinning while processing. Due to this increase in area, metal for trimming, flanging, rolling, or wire beading is typically available in adequate quantities. The blank gauge should be around 30% larger than the finished component's thinnest section permissible to account for stock thinning.
You can usually get one on the outside if you need a reinforcing bead or wired roll over the edge.
Large radii and streamlined or smooth curves help in manufacturing and look better. Make sure to include a radius of at least 3 mm.
Conclusion
Metal spinning is a complicated way to make things. It involves quickly turning flat metal discs or sheets into specific shapes. This process includes choosing the right material, getting the blank ready, setting up the spinning lathe, and using professional spinning tools like chucks and mandrels. With these tools, spinners shape the metal by pressing down on the blank while it spins. Once the metal is in the shape that is wanted, it is carefully looked over and cleaned to make it look better and work better. The speeds vary on the size of the sheet. For sheets 7.5 to 22.5 cm, the speeds are usually between 600 and 1800 pm; for sheets 22.5 to 45 cm, they are between 1200 and 2400 pm; and for sheets 45 to 125 cm, they are between 1650 and 3000 pm. Spinning metal has many benefits, such as making precise parts, decorative art, and complicated patterns.
Metal spinning is a cheap way to make things that give you more design options, saves materials, lets you make prototypes quickly, is stronger and lasts longer, looks better, has shorter lead times, and is good for the environment. It is easy to set up and doesn't need many tools, so it's perfect for making small to medium batches.
Because only one metal blank is used, metal spinning doesn't make a lot of waste, which is good for the earth and saves money on materials. It's also good for industries that need to test and make prototypes of items quickly because it cuts down on lead time. The process also makes the materials better because spinning them makes them harder, which makes lighter, cheaper materials that can be used for parts.
Quick lead times are available for small to medium batch numbers, and the metal spinning process works well and doesn't cost too much. It is the most eco-friendly way to make metal because it uses less material and makes less trash. The full sheet metal disc is used in the process of metal spinning, and the metal bits that are left over are recycled and used for other things.
It is easy and cheap to make spinning tools, and they don't need as much equipment as standard dies for stamping or casting. It can be changed to fit the projected life of parts, which makes it a cheap option for low- to medium-quality needs.
Combination spinning and drawing is often done at the same time. Metal spinning has low prices and can make parts from 1" to 5' long. Spinning, on the other hand, takes more time and skill, and because it takes longer, it might not be good for mass production.
Parts for metal spinning are made by considering things like how easy they are to work with, how far they can bend, how thick they are, how deep they spin, and how many steps there are in the circle. Making hemispherical shapes is harder than making conical shapes. Two-piece roll chucks can make closed parts or complicated shapes. Because the stock area grows a little because it thins, metal is usually available for cutting, flanging, rolling, or wire beading. Large radii and smooth curves are good for both production and looks.
Content Summary
- Metal spinning, also known as "spin turning" or "spin forming," is a technique for shaping metal into various forms.
- This process requires a combination of advanced technology, skilled craftsmanship, and precise accuracy.
- Spinners, the craftsmen, can create anything from simple cylinders to complex sculptures.
- The selection of material is crucial, with options including copper, stainless steel, aluminium, and precious metals.
- Preparing the metal involves cutting a disc or sheet, termed a blank, to the desired size.
- The spinning lathe, an essential tool, rotates the blank at speeds depending on the project's requirements.
- Professional spinning tools like chucks and mandrels are used to shape the metal as it spins.
- Attention to detail is vital, as even minor adjustments can significantly affect the final product.
- Finishing touches might include polishing or coating to enhance appearance and functionality.
- The rotational speeds of the spinning lathe vary based on the dimensions of the metal sheet.
- Metal spinning is notably cost-effective for small to medium-batch production.
- Minimal tooling and setup requirements contribute to lower initial costs.
- The adaptability of tooling, from wood for one-off projects to hardened steel for longevity, optimises costs.
- Excel's integration of fabrication processes with metal spinning offers a one-stop manufacturing solution.
- The method allows for the creation of complex shapes like hemispheres and cones with design flexibility.
- Metal spinning is efficient in material use, producing minimal waste, which supports environmental sustainability.
- Rapid prototyping capabilities make metal spinning ideal for quick product development and testing.
- Spun metal components are often more durable and stronger due to work-hardening effects.
- The aesthetic appeal of spun metal enhances its value beyond practical applications.
- Continuous material work enhances properties, allowing for the use of lighter, cost-effective materials.
- Short lead times for metal spinning ensure quick turnaround for small to medium batches.
- As an environmentally friendly process, metal spinning uses materials efficiently and generates minimal waste.
- The tooling for spinning is less expensive compared to traditional casting or stamping dies.
- Repeated use of tools on a product can increase its hardness and tensile strength.
- Tooling costs are aligned with project longevity, offering customised solutions for each task.
- Design changes are easily accommodated, making metal spinning ideal for prototypes.
- Metal spinning can have a turnaround of just a few days due to in-house tooling capabilities.
- Combination spinning and drawing techniques enhance the versatility of the process.
- Competitive pricing makes metal spinning an affordable option compared to other manufacturing methods.
- The ability to quickly produce prototypes enhances the efficiency of product development.
- Metal spinning accommodates a wide range of part sizes, adding to its versatility.
- The process allows for minimal scrap, further emphasising its efficiency and sustainability.
- Secondary operations are managed internally, streamlining the production process.
- Spinning requires more time and skill compared to some other methods, presenting a limitation.
- It may not be suitable for large-scale production due to the time-intensive nature of the process.
- Design considerations for metal spinning include material workability, bend radii, and thickness.
- Hemispherical shapes and deep components may require intermediate annealing during spinning.
- Two-piece, sectional, or off-centre roll chucks can produce complex or 'closed' components.
- Stock thinning during the process provides extra material for finishing operations.
- Large radii and smooth curves are recommended for ease of manufacturing and aesthetic appeal.
- The process's adaptability allows for quick and cost-effective adjustments during product development.
- Metal spinning supports a broad spectrum of industries, from aerospace to decorative arts.
- The craftsmanship involved in metal spinning results in high-quality, durable components.
- Environmental benefits of metal spinning include efficient material use and recycling capabilities.
- The process's cost-effectiveness is enhanced by the longevity and reusability of tooling.
- Metal spinning's rapid prototyping and short lead times facilitate dynamic product development cycles.
- The strength and durability of spun metal products make them suitable for critical applications.
- The aesthetic qualities of spun metal allow for its use in both functional and decorative contexts.
- Improved material properties through work-hardening extend the range of applications for spun metal.
- The versatility and efficiency of metal spinning make it a preferred method for custom and innovative metalwork.
Frequently Asked Questions
Metal spinning offers advantages such as lower tooling costs, shorter lead times, and the ability to produce seamless, uniform parts without welding or soldering. It is particularly suitable for prototypes and small to medium production runs.
Metal spinning allows for greater design flexibility, minimal material waste, excellent surface finish, and the ability to maintain consistent wall thickness throughout the part, which can be challenging with other forming techniques.
Yes, metal spinning is often used for prototyping due to its flexibility, relatively low tooling costs, and ability to produce functional prototypes for testing and evaluation quickly.
Factors such as part complexity, material selection, tolerances, production volume, lead time, and budget constraints should be considered when determining if metal spinning is the appropriate manufacturing method for a particular project.
Yes, metal spinning can be automated to various extents depending on the part's complexity and the desired production volume level. CNC (Computer Numerical Control) spinning machines offer high levels of automation and precision, making them suitable for mass production.