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6. Metal Spinning, Flow Turning & Flow Forming

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6. Metal Spinning, Flow Turning & Flow Forming ME5603 Metal Forming Technology METAL SPINNING, FLOW TURNING & FLOW FORMING By: A/P Lee Kim Seng METAL SPINNING, FLOW TURNING & FLOW FORMING Flow turning or spinning is the plastic deformation of metal to the shape of a rotating mandrel with forces applied by a tool or roller. A/P Lee Kim Seng METAL SPINNING, FLOW TURNING & FLOW FORMING (Cont..) It is an efficient and economical way of producing radial symmetrical parts such as cones, hemisphere and cylinders etc. A/P Lee Kim Seng A/P Lee Kim Seng A/P Lee Kim Seng Tools Used in Metal Spinning, Flow Turning & Flow Forming A/P Lee Kim Seng Metal Spinning, Flow Turning & Flow Forming Processes in action A/P Lee Kim Seng A/P Lee Kim Seng A/P Lee Kim Seng In conventional metal spinning, a flat blank or preform is formed into another rotationallyrotationally symmetricalsymmetrical shapeshape with the aid of a stick tool or spinning roller. Each element in the blank undergoes appreciable radial displacement from its original position whereas the change in the thickness is virtually zero. A/P Lee Kim Seng A/P Lee Kim Seng Flow turning (sometimes known as power spinning, shear spinning, shear forming, spin forging and hydro spinning), resembles conventional spinning, in that a flat disc is transformed into final shape by localized plastic deformation between a mandrel and a roller. However, during flow turning, each element in the blank retains its radial position. A/P Lee Kim Seng The final wall thickness of the component is given by α tf = to sin o For preformed cone sin α t = t o f 1 sin β β (t1 = to sin ) A/P Lee Kim Seng The pre-requisite for flow turning is axial symmetry, thus allall conicconic sectionssections can be formed provided a mandrel is made for the required section and the roller can be made to describe the required profile. Only one thickness can be produced when flow turning a flat blank with a given thickness at a certain cone angle. A/P Lee Kim Seng A/P Lee Kim Seng Flow forming, sometimes referred to as flow turning of tubestubes, is a rotary point extrusion process. There are two modes of operations, namely the forward and backward methods. A/P Lee Kim Seng A/P Lee Kim Seng Flow Turning Spinning 1. Flow turning is a shearing operation whereas conventional spinning is one of bending and drawing with the inherent problems of spring back and wrinkling. 2. Flow turning requires much higher forces compared to conventional spinning. A/P Lee Kim Seng Flow Turning Spinning 3. In conventional spinning, the deformation zone extends into the unspun flange, and the problem of instability of the flange arises as a result on induced stresses, whereas in flow turning the deformation is localized. 4. In conventional spinning, the thickness remains virtually constant while the blank diameter changes. In flow turning, the thickness is reduced but the blank diameter remains unchanged. A/P Lee Kim Seng Flow Turning Spinning In addition, flow turning process has considerable advantages over the conventional spinning process in forming axi-symmetrical conical components. These advantages include: • Close dimensional accuracy. • Higher output rate because only a single pass is needed. A/P Lee Kim Seng Flow Turning Spinning • Base and unformed rim retain original thickness giving the component added rigidity. • Simple machine operation by semi-skilled personnel. • Lower material and labor cost (less wastage). • Improved metal properties due to work hardening. • Flexibility in production as resetting of the machine is easy and takes little time. A/P Lee Kim Seng Flow Turning The disadvantagesdisadvantages of flow turning process are:- • It is limited to the forming of radially symmetrical, hollow conical parts only. • The ductility and elongation of the material is reduced. • It requires higher forces, thus larger machine capacities, when compared to spinning. • Machine costs are higher. A/P Lee Kim Seng Perhaps one of the greatest drawback to the wider adoption of flow turning or spinning as a production method is the comparatively slow rate of production when compared with other forming processes, such as deep drawing. A/P Lee Kim Seng Some practically aspects: i) Flow turning machine and its applications ii) Flow formability iii) Accuracy, tolerance & surface finish iv) Material properties v) Lubricant vi) Costs vii) NC & CNC machine A/P Lee Kim Seng • Horizontal & Vertical model with various capacities. • 1 to 3 forming rollers. A/P Lee Kim Seng Flow turning machines are suitable or adaptable for metal spinning as well as flow forming – able to form more complex components; often combining spinning, flow turning & flow forming in 1 machine cycle – thus making the process much more flexible & economical. A/P Lee Kim Seng Applications: Flow turning process is used in aircraft and aerospace industries to produce engine, rocket and missile components, such as shrouds, nose cones and motor case cylinder, because of material and cost saving. A/P Lee Kim Seng Many automotive and truck parts such as wheel rims, shock absorber tubes and brake cylinders are being flow turned or flow formed. A/P Lee Kim Seng The process is also adopted for production of convex and concave hollow components, such as sound reflectors, ventilator parts, inlets and container covers. A/P Lee Kim Seng Other applications of spinning, flow turning and flow forming include air handling components such as diffusers, tank ends, centrifuge bowls, radar screen, light reflector, kitchen utensils, washing machine parts and musical instrument components. A/P Lee Kim Seng The main manufacturers of flow turning & spinning machines are Lodge & Shipley Co., Cincinnati Milacron, and Leifeld U. Co. A/P Lee Kim Seng Materials: The range of materials which can be spun and flow turned include most ferrous and non-ferrous materials, such as: • Aluminum and their alloys • Silver and their alloys • Copper and their alloys • Zinc and their alloys • Steel, carbon and alloys such as low carbon steel (< 0.5% C) • Stainless steel • Nickel • Titanium (normally hot 500 – 1100 °C) • Lead A/P Lee Kim Seng • Defined as the maximum reduction achievable during the flow turning processes so as not to confuse with the term spinnability. • Increase with ductility at room temperature. • Deterred by flange wrinkling and wall fracture. Maximum reduction in thickness ≅ 75% (2αα≅≅ 30°) In general, semi-cone angle 12°°≤≤≤ααα≤≤ 80° < 12° – Thinning, metal working required become excessive and problems may occur. > 80° – Amount of ‘working’ of the metal is insufficient to ensure stability. Small cone angle can also be achieved by starting off with a pre-formed. A/P Lee Kim Seng Accuracy – Influence by the feed and the amount of reduction. Surface Finish – Inversely proportional to feed. Tolerance – up to ±0.025mm is claimed in some literature depending on the size and the complexity of the part flow turned. A/P Lee Kim Seng The crystal lattice structure in the metal is distorted; this results in an increase in hardnesshardness, yieldyield stressstress & tensiletensile strengthstrength, with a concurrent reduction in elongationelongation. Metallurgical properties of the final part are betterbetter than those produced by normal press-drawing processes. A/P Lee Kim Seng High nickel alloys & steel components – lubricant is needed to withstand the high pressure and temperature develop due to the intense working. Commonly used lubricant – Beeswax – tallow – yellow soap 1 part of heavy oil to 2 parts of paraffin has proved ideal in flow turning of drums for spin-dryers. A/P Lee Kim Seng Tool friction may also be reduced by flash copper- plating difficult shape. Sulphur or lead lubricant should never be used where annealing is to follow, because their presence causes embrittlement to annealing temperatures. A/P Lee Kim Seng Blank for flow turning & spinning can be flat sheets or plates, forgings, extrusions or castings. Preformed blanks drawn on presses or machined are also widely used. Thus there is considerable material choice and consequently a high potential for cost reduction. A/P Lee Kim Seng E.g. At the Bristol Siddley Engines Ltd., (Now part of Rolls Royce), large material saving occurred when using the flow turning process. A/P Lee Kim Seng Although flow turned components can reduce both the material cost and labour cost it is influenced by the batch quantities. Batch as low as 50 off can be economically formed or flow turned, but normally runs of several hundreds are required to justify flow turning. A/P Lee Kim Seng Before deciding on any process, for example flow turning, spinning and deep drawing, for the production of axi-symmetrical components, there are several factors which may influence the choice, namely: 1) Material and Tool cost per unit (This may vary with batch size) 2) Labour and overhead costs 3) Lead time and delivery requirements 4) Dimensional accuracy of the product and limits of each process 5) Batch quantity 6) The availability of machine equipment A/P Lee Kim Seng Comparative cost chart for producing 6 x 6 in. aluminum shell by spinning and deep drawing A/P Lee Kim Seng The application of NC & CNC machines had a great effect on the spinning & flow turning – permit components to be produced which previously would have been considered impracticable. A/P Lee Kim Seng Advantage of NC & CNC machine over conventional machine include: 1) Faster set-up & change over time 2) Operation by unskilled labour 3) Uniform parts spun or flow turned at high production rate 4) Simplified part programming when using CNC A/P Lee Kim Seng The introduction of NC & CNC greatly increases the complexity & flexibility of the flow turning process. Although NC & CNC has been introduced only recently to metal spinning & flow turning machine, they promise to make an important impact to future high production application.
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