The fact that the spinning method is effective on various metals is a bonus. In addition, this approach can cure several metals. Here is a rundown of some of the most common metals, along with their usual applications and unique difficulties:
Table of Contents
What is Metal Spinning
A metalworking method called metal spinning, spin forming, or just spinning involves utilising a tool or die to shape a metal disc or tube into an axially symmetrical component by rapidly rotating it. The technique is similar to wheel-throwing pottery or woodturning, except that metal is used instead of clay or wood.
Metal spinning is an efficient and multipurpose process for making spherical, conical, or hemispherical components. Parts with intricate geometries and thin walls, such as pressure vessels, fuel tanks, and aircraft components, are frequently made using this material.
The procedure starts with clamping a flat metal ring or sheet onto a mandrel or chuck. The metal is subsequently shaped by applying pressure on it using a spinning tool, which can be a hand tool or a lathe. A spinning tool, usually fashioned from a hard substance like diamond or carbide, is moulded to fit the exact specifications of the finished product. The metal is gradually moulded and stretched into the desired shape while it is spun.
Metal spinning has many uses in the fabrication process. The capacity to fabricate components with intricate geometries and thin walls—achievable, if not impossible, using alternative metalworking processes—is a major benefit.
Metal spinning is quick and effective since it can make multiple pieces simultaneously with little wastage. Parts made using this technology also have a uniform thickness and a flawless surface because of their precision.
Manual spinning, spinning on a lathe, and hydroforming are just a few of the many forms that metal can take. Here are a few of them for your perusal:
Manual Metal Spinning
A more conventional approach is manual spinning, which entails hand-shaping the metal with a spinning tool. Various metal items, such as pots, pans, and ornamental pieces, have been fashioned using this method since ancient times. There are several modern-day uses for manual metal spinning, such as manufacturing one-of-a-kind metal components for many businesses.
CNC Metal Spinning
Using a lathe and a spinning tool, computer numerically controlled (CNC) spinning is a more automated procedure for shaping metal. Precision and repeatability in part production are two of CNC metal spinning's greatest strengths. By ensuring every part is manufactured to exacting standards, the computer-controlled process improves product quality and decreases the likelihood of failures.
Hydroforming
One subset of metal spinning, hydroforming, involves shaping the metal with high-pressure fluid. Hydroforming can create detailed patterns and motifs that standard metalworking procedures cannot. The process is also quite efficient, and the items it produces are accurate and repeatable.
Metal spinning is an excellent method for creating symmetrical components with a round or cylindrical shape. Producing components with intricate geometries and a flawless finish is an efficient, flexible, and economical approach.
Types of Metals for Metal Spinning
Stainless Steel
For uses requiring resistance to corrosion and high temperatures, stainless steel is often chosen. Metal spinning is excellent for creating big, deep vessels without seams. Perfect for use in the kitchen and the medical field.
Forming stainless steel may be difficult due to its work-hardening properties. But, unlike ferritic steel, which is less likely to undergo work hardening, austenitic steel and other types of stainless steel are more likely to do so. An approach to this problem is to anneal the material while spinning periodically.
Carbon Steel
As a material, carbon steel is both inexpensive and malleable. Depending on the carbon content, it shows work hardening to different degrees. Nevertheless, carbon steel's workability can be influenced by the heat treatment it has already undergone, any extra alloying elements and other factors. Although cold-rolled and hot-rolled steel can be spun, the former is more convenient. If you need carbon steel with enhanced corrosion resistance, you may paint it.
Galvanized Steel
Carbon steel dipped into a bath of molten zinc to coat it is called galvanised steel. Protecting the base material with a sacrificial anode boosts corrosion resistance.
Since the spinning process often does not harm the zinc coating on galvanised steel, no post-spinning corrosion prevention is necessary unless the item is cut after spinning.
Aluminum
Because of its malleability, resistance to corrosion, and high strength-to-weight ratio, aluminium is preferred for spinning. Even though it's not very strong mechanically, unalloyed aluminium is the most malleable metal. For this reason, alloy grades are usually the way to go. Because it is less likely to work harden, aluminium metal spinning is both cheaper and easier to work with than stainless steel.
Copper
Because it is very formable and does not easily break or tear when formed, copper is perfect for metal spinning. Its antibacterial characteristics, thermal and electrical conductivity, and suitability for medical usage make it an ideal material. When a high level of mechanical strength is required, copper is not the material to choose. Maybe bronze or brass might work better here.
Inconel
Superalloy Inconel keeps its mechanical strength and resistance to oxidation even when heated to extremely high levels. Inconel requires continuous heating with a flame torch to prevent work-hardening and keep it formable. Inconel 625 is a popular alloy with extensive use in high-stress aerospace applications. Modern methods avoid heating the entire component by focusing the heat with a laser.
Hastelloy
Among the superalloys, Hastelloy stands out for its exceptional resistance to corrosion under extreme stress. Forming a Hastelloy is possible, although it may require annealing several times due to its strong work-hardening tendency, similar to other superalloys and stainless steels.
Titanium
Titanium is a fantastic material thanks to its low density, high strength-to-weight ratio, and remarkable corrosion resistance. Due to its lightweight characteristics, it contributes to reduced fuel consumption, so it is a preferred material for aeronautical applications. Titanium is notoriously difficult to shape because it often requires heating during spinning—usually accomplished with a blow torch—to help shape.
Bronze
The two primary alloying elements found in bronze are tin and copper. Its greater toughness makes shaping more challenging than metals like copper or brass. However, it still has some of copper's advantages, such as strong thermal conductivity and better mechanical qualities, including tensile strength. When compared to copper, bronze's corrosion resistance is far better. If greater strength and hardness are needed, bronze is an excellent substitute for copper because it is easily spun.
Brass
Copper and zinc are the two primary alloying components in brass. Because of its high copper content, brass is resistant to corrosion and biofouling. It is easy to spin because of its outstanding formability. Because of its lustre, brass is popular for adornment items like lampshades.
Benefits of Metal Spinning
When contrasted with other methods of metal formation, metal spinning offers many benefits, including the following:
- Cheaper, faster, and more versatile design options for axisymmetrical components
- Ensuring a Smooth and Superior Building Process
Low Costs
The combination of metal spinning's high speed and minimal material waste makes it a potentially inexpensive manufacturing technology. Using robotic arms to load and unload the machine and post-process the component—such as putting it in a jig for trimming—and automated systems that use CNC spinning machines to make the item can further reduce expenses. You can further reduce expenses by making the forming mandrel from materials that are quite affordable.
Shorter Cycle Times
Metal spinning is the way to go for prototypes or one-of-a-kind components that need to be made quickly. Maximising production with minimal lead times is possible with automated solutions that eliminate downtime between processes.
Maximum Design Flexibility for Axisymmetric Parts
Compared to other methods, such as stamping or drawing, metal spinning creates relatively complex axially symmetrical components. Multi-part specialised mandrels are another option to make components with captive geometry—that is, pieces where the metal has formed around the mandrel but cannot be removed.
Seamless, High-Quality Construction
Metal spinning is the way to go if you want to make containers without the possible weak spots created by welding or brazing. Which is why it's perfect for use in pressure cookers and other similar appliances.
Problems with Metal Spinning
For axisymmetrical components, metal spinning can be a great option. Nevertheless, please be informed that the following are some of the drawbacks of the process:
Snarl
Snarl is shorthand for flaws in the spun component, including creases and folds caused by the material re-folding. These flaws manifest as a result of defective tooling, over- or under-lubrication, or bad technique. But in most cases, bad design and the manufacturing challenges it causes are to blame for these kinds of problems.
Consistency
When spun pieces are made by hand, achieving consistency between them can be very challenging. It is not possible for the operator to consistently apply the same pressure or adhere to the same forming procedures. But a computer numerical control metal spinning machine can get around this.
Ovality
Using metal spinning to make components with a high degree of circularity can be quite challenging. Material spring back and uneven pressure application are two causes of this. Computer numerical control (CNC) spinning machines with multi-point pressure capabilities can solve many of these issues. A certain amount of ovality is inevitable in spinning parts, though.
Long Processing Times
The complete formation of some components necessitates more than one pass. Forming the final section in a single pass is usually not feasible because doing so can cause the metal to break. It may take more time to process if there are multiple passes. This starkly contrasts the far quicker methods of metal stamping or drawing. Nevertheless, It may take longer than alternatives, such as stamping, even if the part is made in a single pass.
Safety Risks
Physically shaping the metal using hand tools, metal spinning—particularly manual metal spinning—can be risky since the operator must be near the spinning metal components at high speeds. It may be tough to justify the expense of a purpose-built CNC spinning machine, but these devices remove much of the danger.
Which Industries Can Use Your Metal Spinning Method?
Metal spinning parts are ubiquitous, permeating nearly every global business.
However, typical sectors comprise:
- Space and Aeronautics
- Farming and Agricultural Tools
- Home Appliances and Equipment Manufacturing
- The fields of architecture, construction, and building
- Vehicle Debris Logistics for Solid Handling and Supply Chains
- Chemical Reaction Methods
- Business Ambience Lighting
- Vehicles Used for Business
- Information exchange
- Power Source: Electrical
- Food Processing Technologies
- Dining Services
- Climate Control, Air Filtration, and Air Handling
- Machines for Industry and Lighting
- The Management of Marine Materials
- Contamination in the Medical Field
- Railway
- Amusement device
- Cooling Appliances and Stoneware
- Roofing Security Items
- Transportation, sanitation, and welding
Conclusion
As a metalwork technique, metal spinning involves quickly turning a metal disc or tube around a tool or die to make a part that is symmetrical along its length. This method is like putting pottery on a wheel or turning wood, but it uses metal instead of clay or wood. It works well and can be used for many things, like making spherical, conical, or hemispherical parts for pressure vessels, fuel tanks, and aeroplane parts.
Metal spinning can be done by hand, with a computer numerically controlled (CNC) machine, or by hydroforming different types of metal. When you do manual spinning, you shape the metal by hand with a spinning tool. CNC spinning, on the other hand, is more automatic and makes it possible to make parts that are accurate and consistent. When you shape metal with a high-pressure fluid, you can make intricate patterns and designs that you can't do with normal welding methods.
People often choose stainless steel because it doesn't rust or react badly with high temperatures. This makes it perfect for making big, deep jars without seams. Carbon steel is cheap and easy to shape. Its work hardening is affected by things like heat treatment and alloying elements.
Molten zinc is used to coat galvanised steel, and aluminium is chosen because it is easy to shape, doesn't rust, and has a high strength-to-weight ratio. Copper is great for metal spinning because it is hygienic, conducts heat and electricity well, and can also be used in medicine. Inconel is a common alloy used in high-stress aerospace uses. However, modern methods focus heat on a small area of a part instead of heating the whole thing.
Hastelloy, titanium, bronze, and brass are all examples of superalloys that don't rust even when they are under a lot of stress. Because it is low in density and high in strength-to-weight, Hastelloy is a lightweight material that can be used in aerospace. Titanium is hard to shape because it gets hot when it spins. Bronze, which is made of tin and copper, is better at moving heat and being stronger than copper. Brass is made up of copper and zinc. It doesn't rust or grow biofouling, and its shine makes it easy to spin.
There are many benefits to metal spinning, such as cheaper, faster, and more flexible design options for axisymmetrical parts, a smoother and better building process, low costs, shorter cycle times, the most design options for axisymmetrical parts, and high-quality, uniform construction. Skunk, consistency, ovality, long working times, and safety risks are some of the problems that can happen when metal is spun.
Metal spinning parts are used in many fields, including architecture, construction, building, agriculture and Agricultural Tools, home appliances and equipment manufacturing, chemical reaction methods, business lighting, information exchange, power sources, food processing technologies, dining services, climate control, air filtration, and air handling, train systems, amusement devices, and cooling systems.
Metal spinning has many advantages over other ways of making metal, such as being cheaper, more flexible, and less dangerous.
Content Summary
- Metal spinning is a process for creating axisymmetrical metal components.
- This method can shape various metals into hollow parts with different forms and sizes.
- Metal spinning is an ancient technique with evidence dating back to Ancient Egypt.
- It's essential for industries requiring symmetrical metal parts, such as aerospace and automotive.
- Stainless steel is commonly used in metal spinning for its corrosion resistance and strength.
- Aluminium is favoured for its lightweight, malleability, and corrosion resistance.
- Copper offers excellent electrical and thermal conductivity, making it ideal for various applications.
- Carbon steel is durable and cost-effective, suitable for parts requiring high strength.
- Galvanised steel, coated with zinc, provides enhanced corrosion resistance.
- Inconel excels in extreme environments with its oxidation and corrosion resistance.
- Hastelloy is known for its superb stress and corrosion resistance.
- Titanium offers a high strength-to-weight ratio and exceptional corrosion resistance.
- Bronze, a copper-tin alloy, is tougher and more corrosion-resistant than pure copper.
- Brass, composed of copper and zinc, is easy to spin and resistant to biofouling.
- The choice of metal significantly impacts the spinning process and the final product's properties.
- Tooling for metal spinning can vary, affecting the cost of production.
- Lower-cost tooling materials can be used for prototyping and low-volume productions.
- Determining material thickness is crucial for achieving desired specifications and tolerances.
- The dimensions of the project should be carefully considered to minimise costs.
- Specifying tolerances can optimise expenses by focusing on critical areas of the component.
- Metal spinning offers a cost-effective solution for manufacturing complex shapes.
- It allows for quick prototyping and customisation with minimal waste.
- Manual metal spinning is a traditional method, ideal for unique metal components.
- CNC metal spinning uses computer-controlled lathes for precision and repeatability.
- Hydroforming, a subset of metal spinning, shapes metal using high-pressure fluid.
- The process is versatile and suitable for creating parts with intricate geometries.
- Metal spinning is faster and more cost-efficient compared to other metalworking methods.
- It allows for the production of seamless, high-quality components.
- However, issues like snarling and consistency can arise, particularly in manual spinning.
- Ovality and long processing times can be challenges in achieving perfect circularity.
- Safety risks are associated with manual spinning due to the proximity to spinning metal.
- Despite these challenges, CNC machines can mitigate many issues, improving safety and consistency.
- Metal spinning is widely used across industries, from aerospace to household appliances.
- It enables the creation of durable, corrosion-resistant parts for various applications.
- The process's flexibility makes it an excellent choice for prototyping and bespoke projects.
- Design considerations, such as material selection and tooling costs, are crucial for successful outcomes.
- Understanding the specific requirements and limitations of metal spinning can lead to better product designs.
- Collaboration with experienced professionals can enhance the project's success.
- Metal spinning contributes to innovation in product development and manufacturing.
- Its environmental benefits, including minimal waste and the use of recycled materials, make it a sustainable option.
- Industries like aerospace, automotive, and medical devices benefit from metal spinning's capabilities.
- The process supports the manufacturing of complex, high-quality metal components.
- Choosing the right metal and tooling strategy can optimise the efficiency and cost-effectiveness of metal spinning projects.
- Metal spinning's adaptability to design changes and material variations supports customisation and innovation.
- Engaging with metal spinning experts can unlock new possibilities in product design and manufacturing.
- The technique's ability to produce seamless parts is particularly beneficial for pressure vessels and similar applications.
- Metal spinning remains a vital manufacturing technique, blending traditional craftsmanship with modern technology.
- It allows for the economical production of small batches and one-off items, as well as mass-produced components.
- Understanding the nuances of metal spinning can lead to better manufacturing outcomes and product performance.
- Metal spinning continues to play a crucial role in various industries, offering a unique combination of versatility, efficiency, and quality.
Frequently Asked Questions
Bronze is known for its strength, durability, corrosion resistance, and attractive patina finish, making it suitable for sculptures, bearings, marine hardware, and architectural accents.
Alloys are engineered to enhance specific properties such as strength, hardness, conductivity, and corrosion resistance, offering versatility and customisation options for specialised applications.
Yes, common alloys used in metal spinning include aluminium alloys like 3003, 5052, and 6061, stainless steel alloys like 304 and 316, and brass alloys like C260 and C360.
The choice of metal affects factors such as formability, tool wear, surface finish, and production costs in the metal spinning process, influencing the selection of spinning techniques and equipment.
Considerations include the intended application, environmental conditions, aesthetic requirements, budget constraints, and compatibility with the spinning process to ensure optimal performance and quality of the finished parts.