Metal spinning is a metalworking process used to make axially symmetrical hollow parts by rotating tubes, pipes, or discs with high speed and deforming over a pre-shaped mold by applying force. This process does not remove metal from the part. It uses a lathe machine, CNC, or rotating machine to clamp and rotate the parts.
Metal Spinning Process
Metal spinning is a simple process. It uses a preformed block, pre-sized metal disc, pressure pad, and tool as the main part. The main motive of this process is to make a product similar to the block.
This block clamped in the chuck of the lathe to rotate at high speed. The pressure plate is connected to the tailstock to apply pressure on the metal disc.
When the lath machine turns ON, the chuck starts rotating at high speed. So, a metal disc is attached to the block by applying pressure with a pressure pad with tailstock. Once it gets fixed, the spinning tool applies pressure on the metal disc to get the required shape.
The tool material that rotates over the workpiece or metal disc is solid brass or hardened steel. It is the front part of the mandrel. As the force increases, the metal disc starts flowing over the block. It requires applying pressure step by step to get a final shape similar to the block.
After the spinning, it requires trimming or finishing to get the desired shape and finish. Trimming reduces the sharp edges of the workpiece.
To get a good surface finish, the workpiece remains rotated at high speed and the duckbill tool is used to get a good surface finish. Dusk bill is a special tool are using for round and flat shapes. It applies less force, and various lubricants like wax or greases help to get a good surface finish.
Simple shapes are easy to make in less time. But for complex shapes, it requires more time because it increases steps as per the block shape.
Tools of Metal Spinning Process
Spoon is the common tool used for the metal spinning process. In some cases, tools are allowed to rotate over the bearing, which reduces friction, heat, and improves its life. To increase the life of tools, it uses ceramic coating.
Some of the tool’s forms with the mandrel and its tip rollers are there. As per the application, the thickness, diameter, size, and shape of rollers can vary.
For cutting sharp edges, carbide cutting tools using. It gives smooth edges to prevent an accident.
Suitable metals for the metal spinning process
Aluminum- It is light in weight material, has good malleability and ductility, is resistant to corrosion, and has good thermal stability. Suitable alloys of aluminum are 7075, 1100, 6061, 2024, and 5052. It using for making drums, decorative parts, kitchenware, and utensils.
Stainless Steel- It is resistant to chemicals and corrosion because of the addition of molybdenum. It has high strength, is rigid, tough, and withstands high pressure.
Carbon steel- It is a hard type of material. It is less malleable and ductile. These are used for heavy-duty applications in the automotive, aerospace, and construction industries. It is common for making vessels, and tanks.
Brass- It is an alloy of copper and zinc material. It is resistant to corrosion, good thermal conductivity. It using for making decorative parts, equipment, musical instruments, pipes, and electronics appliances.
Bronze- It is an alloy of copper and tin with the addition of other metals like manganese and phosphorus. It is stronger than brass. It using for a high-strength applications like engine parts, musical instruments.
- Domed with flange
- Semi elliptical
- Flanged, dished and flued
Advantages of Metal Spinning
- It is easy to perform multiple operations in one go.
- It does not remove the metal like other processes. So wastage is less.
- It is a simple process to make symmetrical parts.
- The time required for this process is less.
- Due to its low tooling cost, it is a cost-effective process.
- It is easy to automate.
- It is a simple process because the same size of the part is easy to make rather than the casting, forging, and forming process.
- No need for a seam to join two pieces.
Disadvantages of Metal Spinning
- Small dents or cracks in part are not easy to repair. It requires scraping it.
- It makes only round and symmetric parts only.
Applications of Metal Spinning
- The metal spinning process using in aerospace, defense, appliances, paper, healthcare, and more industries to make various parts.
- Using for making vessels and cylinders, engine parts, rocket noses, mixing bowls, and more.
- Using for making ventures, parabola shapes, cones, tank heads,