Metal spinning is a common metallurgical process that transforms a blank into an axially symmetrical part or component with a hollow interior. Machinists use lateral force to press the rollers into your parts in a high-speed rotating mandrel. The result is a custom format that can be used in countless applications.
This is because spun metal does not lose material volume or density during production. Instead, the part is subjected to compression and tension forces to achieve the desired effect. And while certain types of metals may react differently to spinning or experience a minimal decrease in thickness, the overall characteristics of the finished product are indicative of this less invasive machining method.
What is metal wiring used for?
Also known as spin forming, metal spinning is usually performed by hand or with an advanced CNC lathe and is one of the most beneficial methods when rounding metal components for practical and/or decorative purposes. However, in many large-scale metal fabrication projects, the lathe can be automated. In turn, this helps accommodate specifications for accuracy, consistency, product complexity and lead time.
In fact, metal spinning is often the preferred machining technique for a wide range of manufactured products, from common household items and durable kitchenware to specialty instruments and aerospace parts. Meanwhile, almost any ductile metal can be spun by skilled hands, including high-strength alloys. That's why you'll find spun metals in modern architecture, innovative art, contemporary lighting, and countless public amenities.
DID YOU KNOW: Despite the often interchanged name, conventional metal spinning and shear forming are two entirely different CNC machining processes.
Metal vs. Metal Wiring shear formation
Whether the blank is flat or a preformed sheet metal, it is important to understand the differences between conventional metal spinning and shear forming. Metal spinning involves using a chuck and a manual or CNC lathe to shape a workpiece, while shear forming involves using two rotating discs that cut the part into a specific shape – without the use of a chuck. .
Let's dive a little deeper:
Conventional Metal Wiring
Conventional metal spinning is a process of shaping a flat metal disc or sheet using a tool called a mandrel, which rotates at high speed while the metal is pressed against it with a roller or other tool, creating a hollow, symmetrical part.
The depth of the part increases as the diameter is reduced, making conventional metal spinning one of the simplest and most affordable tooling techniques available.
Shearing/Forming
Shear spinning, also known as shear forming, is a metal spinning technique that involves stretching a metal part over a mandrel using high-pressure rollers. Unlike conventional metal spinning, shear forming reduces the thickness of the material and at the same time reduces the diameter of the workpiece.
Shear forming requires more precise machining and tool structures than conventional metal spinning and generates more heat during the process, requiring the implementation of cooling. Be sure to ask your machining team which coolants are best for the metals and processes you are using.
Common Types of Spun Metal
Almost any ductile metal can be spun, but some metals can be more difficult to spin due to their physical properties, such as hardness or ductility. In these cases, specialized techniques may be required to achieve the desired result. Additionally, the thickness of the metal being spun can also affect the ease of the spinning process, with thinner gauges generally being easier to spin than thicker gauges.
The most common metals, including some precious metals, that can be spun are:
- Titanium
- Aluminum
- Bronze
- Copper
- Steel
- Stainless steel
- Brass
- Hastelloy
- Gold
- Silver
Because this machining technique is primarily used to manufacture hemispheres, parabolas, venturis, cylinders, and cones, it is generally reserved for specialized CNC machinists, skilled craftsmen, and experienced hobbyists with appropriate training and equipment who know how to manipulate metals according to their innate properties. . . In turn, a unique design emerges, despite the obvious advantages and disadvantages of the process.
It should be noted that although almost any ductile metal can be spun, there may be limitations based on the size and shape of the part being spun, as well as the machines and tools available. Additionally, some metals, such as those with low melting points, can be more difficult to spin due to the heat generated during the process.
The Pros and Cons of Metal Wiring
Metal spinning is not only an ideal machining method for prototype design and innovative product development, but also involves the following advantages and disadvantages:
Pros
- The entire metal part is used to create the finished product, resulting in minimal waste and lower material costs.
- Spun metal projects typically produce less waste than conventional metal forming methods.
- Overall tooling costs are relatively low compared to other machining methods.
- The technique is cost-effective and can help reduce lead times for small to medium-sized production runs.
- Metal spinning is a simple and efficient manufacturing process that can be used to develop innovative products.
Cons
- Surface irregularities or imperfections may occur during the spinning process, which may affect the quality of the finished product.
- Depending on part specifications and tolerances, some parts may fail inspection due to imperfections.
- Consistent product quality can be difficult to achieve with this method as it depends on the skill and experience of the machinist.
- The machining conditions of each part must be carefully controlled to ensure the best possible result.
NOTE: If you are controlling spun materials in a CNC machine shop, check the offsets to determine the best machining conditions for each part.
