Creating axisymmetrical components for various industries is made possible by the great skill of metal spinning. It is one of the earliest methods for making hollow metal parts, and evidence of it dates back to Ancient Egypt.
Through our collaboration with designers, manufacturers, and other craftspeople, we have learned about the many challenges they face when developing new product ideas. To ensure you get the most out of the Metal Spinning Process, we have prepared this straightforward tutorial for your convenience.
If you're planning a metal spinning project, we hope the following design advice will be helpful.
Table of Contents
Metal Spinning Project Design Advice
Material Selection
Metal spinning works with several different types of metal alloys. Each metal offers distinct qualities and performance improvements. Your planned components' tolerance requirements, specs, and needed strength will determine the basic metals and finishes you must choose from. Proper material suggestions and selection can be achieved through close collaboration with your part fabricator.
Some of the most well-known and reliable metal spinning choices are listed below.
Stainless Steel
The transportation, building, and aerospace sectors use aluminium extensively. The low price, lightweight, and malleability of aluminium are three of its most desirable qualities. Components of this low-density metal can be extremely useful without adding unnecessary weight to complex machinery or equipment that must adhere to strict weight regulations. Corrosion resistance is another one of its well-known qualities.
Copper
Because of its high degree of utility and outward attractiveness, copper is used in commercial, industrial, and residential items. Its corrosion resistance and antimicrobial qualities make it ideal for outdoor or high-contact purposes. Its electric and thermal conductivities are second to none. From a manufacturing perspective, copper's flexibility allows for the rapid fabrication of intricate part designs.
Carbon Steel
You won't believe how long carbon steel lasts. Stronger and more inflexible metals are those with a higher carbon content. Carbon steel is perfect for uses requiring many parts with a high strength capacity because it is affordable and durable. This metal is completely recyclable and has an easy-to-follow technique for painting and coating.
Brass
Brass, made of copper and zinc, is attractive, easy to work with, and corrosion-resistant. And it's a good conductor of both heat and electricity. Due to the presence of additional elements, brass possesses greater strength compared to pure copper. Select the right brass alloy to add ductility, low-friction properties, and malleability to the workpiece.
Hastelloy
Because of its construction, Hastelloy can resist both severe stress and corrosion. It is resistant to various acids, including sulfuric and hydrochloric acids. Also, the metal's resilience to tension and temperature instability makes it a breeze.
Titanium
Built to withstand extreme tension and corrosion, Hastelloy is a material of choice. It can withstand many different acids, including hydrochloric and sulfuric acids. The metal's resistance to stress and temperature fluctuations further makes it easy to work with.
Inconel
Inconel, like Hastelloy, performs admirably even when subjected to the harshest environments. It is second to none in terms of resistance to oxidation and corrosion. Additionally, the metal is resistant to extremes of both heat and pressure. Inconel is perfect for demanding industrial settings due to its exceptional strength.
If you choose the correct metal, it may be spun precisely to meet your thickness and specification needs. Finding the correct metal before making a prototype or running a production run can help minimise costs and waste.
Tooling Cost Considerations
Metal spinning tooling, like workpieces, can be tailored to suit the requirements of an individual project. Tools produced from less costly metals can help low-volume productions save money.
Cost-effective hardwood tools can handle prototype, low-volume, and soft metal orders, making them ideal interim tools. Aluminium and softer steels are used to make permanent tools with a soft edge, which are designed for limited manufacturing runs. Tools must be toughened for longer production cycles or for spinning harder metals.
The mandrels used in metal spinning procedures are shafts or spindles subjected to the comparatively gentle forces required to spin metal components. A lot depends on the mandrel's craftsmanship and quality and how accurate and functional the finished parts are.
Metal spinning tooling materials impact overall costs, but compared to other manufacturing techniques, this metal forming service is still quite inexpensive. Simple turning and milling processes allow manufacturers to create mandrels of excellent quality.
Compared to making dies, utilising other techniques that are extremely labour-intensive, or utilising tools that necessitate a lengthy lead time, this is far easier. Spin-forming tooling is more affordable so that initial manufacturing costs can be cut by 80% to 90%.
Defining Your Material Thicknesses
Determining the project's thicknesses follows thoroughly evaluating the materials you wish to use for the product or its components.
For example, projects with tight corners will thin the material more than those with big corner radii. The component's length is another critical factor to think about. If the material is too thin, it will stretch and "rip" along certain dimensions.
Forming a component takes more time when the material is thicker since it is tougher to work with. The increased labour needed to complete the process will affect your project's budget.
Deciding On Your Dimensions
Think about your measurements while you decide on the material thickness.
By this point, you should have a firm grasp of the purpose of your project and, by extension, its size, which is particularly true if your project is a sub-assembly component.
You can save even more money by reducing the size of your components, which will significantly impact the cost.
Tolerance Requirements
The overall expense of any metal spinning job will rise if precise tolerances are necessary. It is critical to determine the maximum allowable part thickness while maintaining expected and specified performance since the fabrication process naturally thins the metal.
For example, a sidewall can necessitate a different thickness than corners, so it's important to note that different parts of the item may have varying thickness requirements. Your project can be more cost-effective by specifying thickness and tolerance levels at the crucial areas.
Metal spinning is quite versatile and can accommodate a wide range of thickness needs.
Perform A Cost Analysis
The production community ranks metal spinning among the most efficient metal-forming procedures. In cases where procedures optimised for large-scale manufacturing would render small-batch production prohibitively expensive, it offers additional benefits.
Metal Spinning has been a lifesaver for many people in recent years regarding affordable prototypes and bespoke projects. That's why you should determine your budget before deciding whether Metal Spinning is a good fit.
The metal spinning process can harden the material; thus, there are situations where lighter, cheaper materials are preferable. This further improves the process compared to other methods of metal formation.
The component starts as sheet metal discs but is fully utilised; thus, there is less waste, and the project cost is further reduced. When calculating the value of Metal Spinning, remember to include these and any other benefits mentioned in the referenced publications.
Define The End Goal
Make sure you know exactly what you want before fabricating the part. Parts that use spin forming's characteristic round shapes are the most feasible for the process, which results in circular components.
Speak With A Design Consultant
Speaking with industry professionals is our last piece of advice for your Metal Spinning project. If you have any queries or would like more information about the procedure or the craft's capabilities, our team is here to help.
With over 200 years of experience between them, the metal spinning specialists on our team can answer any questions you may have about materials, their effects on price, tolerance limits, the effects of different finishing procedures, and ways to cut expenses.
The Benefits of Metal Spinning on Complex Components
Metal Spinning For Complex Parts
Metal spinning provides several benefits, making it an excellent choice for producing intricate components. Now, we will examine a few of these benefits:
Versatility
Making complicated components in various sizes and forms is one of the process's strongest points. Metal spinning allows for the creating of precision-formed components with seamless, symmetrical surfaces, regardless of their shape (cylindrical, conical, hemispherical, or otherwise).
Cost Savings
When compared to other production methods, metal spinning offers considerable cost reductions. Minimal material waste during spinning is a crucial factor. With metal spinning, material loss is lower than subtractive procedures like machining because the process begins with a prepared blank that nearly matches the final shape. In addition to reducing labour costs and streamlining manufacturing, the efficiency of this process adds to the total cost-effectiveness.
Time Efficiency
Because of the efficiency of the spinning process, manufacturing and lead times are reduced. Quicker turnaround times for complicated products are achieved by eliminating the need for sophisticated tooling setups and expensive machining operations. Metal spinning is perfect for fast-paced manufacturing settings and tight deadlines because of the simplified workflow from concept to finished product, which enables efficient production scaling.
Design Flexibility
The design freedom metal spinning offers is second to none, allowing for alterations and customisations during production runs. This technology permits small tweaks, unlike inflexible moulds or dies, which accommodates design changes without incurring hefty retooling expenses. This adaptability is priceless in sectors that rely heavily on quick product iteration, customisation, and prototyping.
Metal spinning is an attractive option for complicated components because of its adaptability, efficiency, speed, and low production costs. Companies may optimise production costs, satisfy varied design needs, and get high-quality components using these benefits.
Limitations and Considerations
Metal spinning has many benefits, but there are a few things to remember and limits to be aware of before making complicated parts. Let's have a look at these elements:
Possible Restrictions Or Limitations
The unique needs of the intricate components will determine whether metal spinning has any constraints. For example, problems with material deformation or stability during spinning could arise for components with extremely thick or thin walls.
Further machining or secondary processes may be necessary to accomplish the intended outcomes for complicated geometries with intricate features or sharp edges. It is essential to thoroughly assess the practicality of this production method for every distinct component design.
Aspects That Influence Efficiency
The profitability of metal spinning for complicated components can be affected by several factors. Material selection is crucial because various metals have varied degrees of malleability, ductility, and cost.
Part designs can also affect cost-effectiveness in various ways; for example, specialised tooling and additional time may be required for very detailed or distinctive shapes. Taking production scalability into account is crucial, as investing in tooling or automation up front to optimise cost efficiency may be necessary for larger quantities.
Metal spinning can be useful for manufacturers looking to produce complicated parts, but only if they know the constraints and consider aspects like material choice and part complexity. With enough forethought and preparation, you can get the most out of metal spinning and avoid its drawbacks.
Conclusion
The skill of metal spinning makes it possible to make axisymmetrical parts for many businesses. It has been used since Ancient Egypt and can help designers, makers, and craftspeople come up with new ideas for products. Picking the right material and tools is very important for getting the most out of the metal spinning process.
Aluminium, brass, copper, carbon steel, hastelloy, titanium, and inconel are all well-known metals that can be spun. Picking the right metal can help cut down on costs and waste because each one has its own special traits and ways of improving performance.
The cost of tools can also change the price of metal spinning projects. For small-scale products, tools made from less expensive metals can help save money. For permanent tools with a soft edge, aluminium and softer steels work best. The mandrels that are used in metal spinning can change the overall cost, but the process is still pretty cheap compared to other ways of making things.
To figure out the project's sizes, you need to carefully look at the materials you will use for the whole thing or for its parts. Things that are thin may stretch and "rip" along certain dimensions, while things that are thick may take longer to shape.
Choosing the size of the job is very important because it can have a big effect on the cost. You can save even more money by making the parts smaller if you think about what the project is for and how big they are.
Metal spinning is a flexible and effective way to shape metal that can be used for a wide range of thickness requirements. Because it is flexible, efficient, quick, and cheap to make, it is a great choice for making complicated parts. The process can make materials harder, which lets them be used for cheaper, lighter materials. By starting with sheet metal discs that are fully used, metal spinning also cuts down on trash and project costs.
To get the best result, it's important to know what the end goal is before making the part. The process works best on parts that are round, so the final products are circular. Talking to people who work in the field can teach you a lot about products, how they affect price, tolerance limits, finishing methods, and ways to cut costs.
Metal spinning has many benefits, such as being flexible, saving money and time, and letting you make different designs. It lets changes and customisations be made during production runs, which makes it perfect for factory environments with tight deadlines and a lot of activity. But there are some things that might not work right and things to think about when making complicated parts.
Possible limitations include material deformation or instability problems for parts with very thick or thin walls, as well as things that affect efficiency, like the choice of material, the design of the part, and the ability to make more of them. Manufacturers can get the most out of metal spinning and avoid its problems by knowing these limits and taking things like the choice of material and the complexity of the part into account.
Content Summary
- Metal spinning is a skilled process for creating axisymmetrical components for diverse industries.
- This ancient method dates back to Ancient Egypt, showcasing its long-standing relevance.
- It enables the production of hollow metal parts with varying shapes and sizes.
- Collaboration with designers, manufacturers, and craftspeople is crucial for successful product development.
- Material selection plays a key role in metal spinning, influencing the final product's qualities.
- Different metals offer unique benefits, such as strength, corrosion resistance, and aesthetic appeal.
- Stainless steel, aluminium, copper, carbon steel, brass, Hastelloy, titanium, and Inconel are popular choices for metal spinning.
- Each material suits specific applications, from aerospace components to decorative items.
- Tooling costs can significantly impact the overall expense of metal spinning projects.
- Tooling materials range from inexpensive metals for low-volume productions to hardened tools for extensive runs.
- Mandrels are essential in the metal spinning process, affecting the accuracy and functionality of parts.
- Despite the cost of tooling materials, metal spinning remains an affordable metal-forming service.
- Defining material thickness is crucial for achieving the desired specifications and tolerances.
- Projects with tight corners or specific dimensions may require adjustments to avoid material thinning or tearing.
- Thicker materials require more labour, influencing the project's budget.
- The dimensions of the project should be carefully considered to minimise costs and waste.
- Tolerance requirements can raise the cost of metal spinning jobs; specifying thickness and tolerance levels can optimise expenses.
- Metal spinning is efficient and can accommodate a wide range of thickness needs, making it versatile for various applications.
- Cost analysis is vital to determine if metal spinning is the most cost-effective approach for a project.
- Lighter, cheaper materials may be preferable for certain applications due to the hardening effect of the spinning process.
- The goal of the project should be clearly defined to ensure the design is feasible for metal spinning.
- Consulting with a design consultant can provide valuable insights and optimize the design process.
- Metal spinning is especially beneficial for producing complex components with precision and cost-efficiency.
- Its versatility allows for creating parts of various sizes and shapes, from cylindrical to conical.
- Compared to other manufacturing methods, metal spinning offers significant cost savings due to minimal material waste.
- The process is time-efficient, making it suitable for projects with tight deadlines.
- Design flexibility in metal spinning allows for easy modifications during production.
- While metal spinning has many advantages, there are limitations to consider, such as material deformation and the need for secondary processes.
- Material selection, part design, and production scalability are critical factors influencing the cost-effectiveness of metal spinning for complex components.
- Understanding these limitations and considerations can help maximise the benefits of metal spinning while avoiding potential drawbacks.
- Proper planning and collaboration with experienced professionals are essential to successful metal spinning projects.
- Metal spinning contributes to the innovative development of products across various sectors.
- The process's adaptability and efficiency make it a preferred choice for both prototyping and mass production.
- It supports environmental sustainability by producing minimal waste and allowing the use of recycled materials.
- Metal spinning strengthens materials through the realignment of their grain structure, enhancing durability.
- The choice of metal affects the project's cost, performance, and appearance, making material selection a critical step.
- Tooling for metal spinning can be customised to meet specific project requirements, offering flexibility in production.
- The quality of mandrels directly impacts the precision and quality of the spun components.
- Material thickness and part dimensions should be carefully planned to ensure the success of the spinning process.
- Specifying tolerances can help focus attention on critical areas of the component, optimising manufacturing efficiency.
- Conducting a thorough cost analysis can identify potential savings and inform material selection decisions.
- Clearly defining the project's goal guides the design process and ensures the feasibility of using metal spinning.
- Seeking advice from design consultants can enhance the project's outcome by leveraging expert knowledge.
- For complex components, metal spinning offers a blend of design flexibility, cost efficiency, and production speed.
- Awareness of the process's limitations encourages proactive planning and creative problem-solving.
- Considering material properties, tooling options, and production volumes can optimise the use of metal spinning for intricate designs.
- Metal spinning's environmental benefits align with sustainable manufacturing practices, making it an attractive option for eco-conscious projects.
- The process's ability to accommodate design changes and material variations supports innovation and customisation.
- Engaging with metal spinning experts can unlock new possibilities in product design and manufacturing.
- Metal spinning remains a vital manufacturing technique, combining traditional craftsmanship with modern technology to meet contemporary needs.
Frequently Asked Questions
Surface finishes like polishing, brushing, anodising, painting, or powder coating can enhance the aesthetics, corrosion resistance, and functionality of metal spinning designs, depending on the application.
Designers should simplify features, minimise tool changes, reduce material waste, and consider the capabilities of spinning equipment and operators to streamline the manufacturing process.
Common pitfalls include overly complex geometries, inadequate material selection, insufficient consideration of tolerances, and designs that are difficult or costly to manufacture through spinning.
Effective communication between designers and manufacturers is crucial for translating design intent into manufacturable parts. Collaboration helps address technical challenges, refine designs, and optimise production processes.
Iterative design involves refining and optimising designs through multiple iterations based on feedback from prototype testing, manufacturability assessments, and continuous improvement efforts, leading to superior metal spinning designs.