TABLE OF CONTENTS

1. INTRODUCTION

2. THOERY

3. OBJECTIVES

4. MATERIAL AND METHODS

5. DISCUSSION

6. REFERENCES
INTRODUCTION

There are various types of processes which are used to form different kinds of shapes using sheet metals
in the manufacturing industry. This practical is based on the spin forming and shear spinning processes.

THEORY

A Metal spinning, sometimes referred to as spin forming or spinning, is a metalworking technique in

which a metal disc or tube is rapidly rotated and shaped into an axially symmetric object. Commercial
uses include the nose cones of rockets, kitchenware, gas cylinders, brass instrument bells, and public
garbage bins: From aluminium or stainless steel to high-strength, high-temperature alloys, practically
any ductile metal can be produced. Only the size of the available equipment affects the diameter and
depth of the manufactured pieces. Either a CNC lathe or a human hand can spin.

Shear forming, also known as shear spinning, differs from conventional metal spinning in that the final
component's area is roughly equal to that of the flat sheet metal blank in the latter and little to no
reduction in wall thickness occurs, whereas in shear forming, a reduction in wall thickness is induced.
Controlling the distance between the roller and the mandrel allows one to get the desired final wall
thickness.

OBJECTIVES

• Understand the concepts of spin forming and shear forming processes.

• Develop layout and pattern on sheet-metal using correct techniques.
• Fabricate articles using appropriate sheet-metal forming tools, machines and methods.

MATERIALS AND METHODS

METAL SPINING: -

Metal spinning is a manufacturing technique which is used from ancient times to form different types of
shapes using metals. Early days this was basically a low volume manufacturing/fabricating process due
to the requirement of high skilled labour and basic/fundamental machines and tools which were used for
them. With the development of manufacturing technologies, now this metal spinning process can be
used for high-volume production as well.

Materials which can be used for metal spinning process

• Aluminium
• Copper
• Brass
• Stainless and cold-rolled steel

Discs or metal tubes are formed in to required axially symmetric parts. This can be done in a CNC lathe
or by human power in a primitive lathe. Process follows below procedure.

1. Pre-formed block will be mounted in the drive section of a lathe.

2. Using pressure pads which is attached to the tailstock, a pre-sized metal disc will be clamped
against the metal block.
3. Both metal block and the disc will start rotating together when turn on the lathe.
4. Then using various types of levered tools force should be applied on the metal disc to get the
shape of the attached metal block.
5. When forming complex shapes, different metal blocks with different shapes should be clamped
and follow the same steps.
 6. Mandrel is used when surface finish of the final product is crucial.

SHEAR FORMING: -

Shear forming is a very similar process to metal spinning. This can be used
to produce light weight components. Area of the final product and area of
the initial metal sheet will be equal in this process. In this process
reduction of wall thickness may occur. Procedure and the materials which
are used to perform this both metal spinning and shear forming process is
similar.

DISCUSSION

1. Process parameters used for controlling the metal spinning in lathe.

Feed Ratio: -

Feed ratio is defined as the relationship between spindle speed and roller feed rate. The original
blank thickness can be maintained with a high feed ratio. Additionally, it results in surface finish
issues and material failures. The tool forces, wall thickness, spinnability, surface polish, and
spring back of the metal spinning process are all significantly impacted by changes in feed ratio.
Larger feed ratios will result in higher tool forces. Low feed ratio would cause an excessive
amount of material to flow outward, which would needlessly thin the blank but result in a better
surface polish. Low feed ratio is excellent for spinning since it produces a good surface quality
and prevents component failure. The feed ratio for mild steel is 1.8 mm/rev and 0.9 mm/rev for
aluminium.

Feed Rate: -

One of the key factors impacting formability and forming quality is the roller feed rate. The feed
rate is the distance that the tool moves into or along the work piece each time. It can be expressed
as mm/sec or mm/min. Wrinkling and a rough surface finish could happen as a result of the high
feed rate. A decrease in feed rate will result in a better surface finish, whilst an increase in feed
rate will make a work piece fit to a mandrel and result in a rougher finish. The number of pulse
signals for mandrel rotation, mandrel feed, and roller feed are kept constant for a predetermined
amount of time in order to achieve synchronous motion control of the mandrel and roller. The
roller move from mandrel slope is set at 2.4 mm/sec during one path of spinning.

Spindle speed: -

When spinning at a fast speed, the best quality is attained for the majority of components. Impact
of mandrel speed on tool forces is minimal. He makes the case that the mandrel speed has no
impact and provides a wide range of possible mandrel speeds. The change of axial and radial
forces barely responds to rotational speed. Spindle speed for aluminium is between 800 and 900
rpm.

Temperature: -

If the machine's capacity is insufficient for cold forming the component or if the alloy ductility
is too low, it may be necessary to use elevated metal temperatures during metal spinning to
minimize the flow stress and raise the ductility of the component. Although spinning is normally
done in a cold environment, thick parts and materials with high strengths occasionally require
 heating to lessen the forming pressures. In this technique, a hand-held oxyacetylene flame is used
to heat the sheet metal. The blank can occasionally be heated with hot air.

Lubricant: -

When spinning, a lubricant is almost usually utilized. The substance utilized functions as a
coolant and lubricant. Due to the high quantity of heat produced, a water-based coolant, such as
an emulsion of soluble oil in water, is most frequently utilized. The work pieces, mandrels, or
both are occasionally coated with the lubricant before spinning aluminium, stainless steel, or
titanium. When the spinning machine's load capacity is insufficient for cold forming the preform
or when the work metal's room-temperature ductility is insufficient, an increase in the forming
temperature may be necessary to reduce the flow stress and raise the perform’ s ductility. Great
care must be taken when choosing and using a suitable lubricant when operating at high
temperatures.

Regardless of the preform composition or shape or the kind of metal-spinning equipment being
used, lubricants are often required in all metal-spinning operations. Typically, lubricants are
needed both before and during formation. The preform’ s rotational speed and the tenacity of the
utilized lubricant both affect how much lubrication is required during spinning. Throughout
spinning, the lubricant must stay affixed to the revolving preform. Ordinary cup grease is widely
applied. It can be heated to make it less viscous so that it can be applied more easily. Other
lubricants used for metal spinning include soaps, waxes, and coloured drawing compounds; when
choosing the most appropriate lubricant, the lubricant's ease of removal following forming must
be taken into account.

2. Capabilities and limitations of metal spinning as a manufacturing process.

Capabilities: -

• In a single setup, many procedures can be carried out.

• Tooling changes can frequently be used to make changes to part designs, especially if the
change involves a reduction in size.
• fewer waste products are produced.
• Guarantees a better level of reliability for components that perform structural functions.
• Tolling cost is low.
• Realigns the metal's grain structure, which enhances metallurgy. Because of the increased
tensile strength, lighter gauge material can be employed in the same application.

Limitations: -

• Shape and size restriction

• It was challenging to maintain the spinning conditions.
• Can have small indentations and imperfections of the last product due to unskilled labour.
• If a crack is formed on the surface, it has to be removed.
3. Deep drawing Vs metal spinning

Deep Drawing Metal Spinning

 Roller force is acted in tangential, radial and
Force is acting in the downward direction.
axial directions.

Almost any form can be made as work

Cylindrical shells and cups can be produced.
pieces with rotational symmetry.

Components with high strength to work ratio

It is not possible.
can be produced.

Comparatively low surface finish and It is feasible to achieve high dimensional

dimensional accuracy. accuracy and surface finish.

Compressive stresses are generated Compressive stresses are generated

circumferentially in deformation zone. tangentially in deformation zone.

REFERENCES

[1] “International Journal of Application or Innovation in Engineering & Management

(IJAIEM),” Ijaiem.org. [Online]. Available: https://www.ijaiem.org/Volume2Issue2/IJAIEM-
2013-02-27-041.pdf. [Accessed: 21-Sep-2022].
[2] “Advantages & disadvantages of metal spinning-News Center-Nanjing Lumaker Metal
Spinning., Ltd,” Lumaker.com. [Online]. Available: http://lumaker.com/info-8.html. [Accessed:
21-Sep-2022].
[3] S. Ibrahim Jr, “The advantages of metal spinning,” Helandermetal.com. [Online]. Available:
https://blog.helandermetal.com/blog/bid/70781/the-advantages-of-metal-spinning. [Accessed:
21-Sep-2022].
[4] A. Jadhav, S. Chaudhari, P. G. Scholar, and H. M. Tech, “Design of metal spinning parameters
for general lathe,” Ijedr.org. [Online]. Available:
https://www.ijedr.org/papers/IJEDR1403046.pdf. [Accessed: 21-Sep-2022].
[5] Wikipedia contributors, “Shear forming,” Wikipedia, The Free Encyclopedia, 11-Oct-2021.
[Online]. Available:
https://en.wikipedia.org/w/index.php?title=Shear_forming&oldid=1049409914.
[6] Researchgate.net. [Online]. Available: https://www.researchgate.net/figure/Principle-of-shear-
forming_fig1_45130768. [Accessed: 21-Sep-2022].
[7] Wikipedia contributors, “Metal spinning,” Wikipedia, The Free Encyclopedia, 09-May-2022.
[Online]. Available:
https://en.wikipedia.org/w/index.php?title=Metal_spinning&oldid=1086974357.