The Facts Behind Metal Spinning And Hydroforming

It is common to think of metal spinning and hydroforming as highly specialised and targeted metal-forming techniques. Consequently, many engineers need to know how useful these methods are.

Hydroforming and metal spinning are the most common industrial processes used to make many products, including gas cylinders, lighting gear, musical instruments, satellite dishes, etc. You may choose the most appropriate metal-forming technique for your needs by learning about the advantages of each procedure.

Hydroforming and metal spinning are the most effective and efficient techniques for producing high-quality, long-lasting metal components and parts.

Parts and components made with the hydroforming technique are robust and well-built, and there is almost little waste. One common method for making complicated components and parts out of flexible materials is the inexpensive and widely used hydroforming process.

What Is Metal Spinning?

The process of metal spinning, also known as spin forming, involves shaping metal discs using methods that are conceptually comparable to those used in the sculpture of clay pots. Metal spinning can be manually or automated using CNC lathes; the latter is more common for smaller production runs. Stainless steel dishes, gas cylinders, brass instruments, and bowls are some of the common metal components spun into production.

Spinning metal allows for the creation of any ductile metal, including:

• Aluminium
• Metal: Stainless
• Alloy Steel Gold Brass
• Steel Titanium Hastelloy

Metal spinning is a cold forming, yet it can also be a hot forming technique, depending on the material.

Technicians can use a torch to hot-form a component when cold-forming isn't an option. With the item heated, it can be easily shaped or necked to smaller diameters with low effort and work hardening.

What Is Metal Spinning In Manufacturing?

This is for all you machinists who have ever wondered what goes into making those pieces that look like bowls and top hats. For metal spinning to occur, a mandrel that has been machined to match the intended workpiece's dimensions and shape is used to gently push metal sheets over it.

The flow is improved wherever work hardening is an issue, such as in confined spaces, around corners, or during a "cold" operation. You might need a blowtorch to soften the metal.

Superalloys like titanium and Inconel and ductile metals like aluminium, copper, brass, carbon, and stainless steel are all good candidates for metal spinning.

For example, a bell-shaped mandrel would be mounted onto a lathe spindle to create a stainless-steel bell. The mandrel can be manufactured from metal, hard plastic, or wood for tasks requiring a higher production volume.

A thin disc, about 1/8 of an inch thick (or more or less, depending on the bell's size), is required to be slightly longer than the outer surface's maximum length. Some specialty businesses have suggested that materials with a thickness of 1 inch or more can be spun.

Types Of Metal For Spinning

Aluminium, stainless, carbon, and high-performance alloys are just a few examples of ductile metals that can be created. Machine intricate curves, narrow grooves, and other complex features can be the machine with a single cycle.

Comparable in design to traditional turning centres, metal spinning lathes have indexable tool holders that permit the operator to swiftly and easily execute secondary turning operations and edge detailing without interrupting the process for setup.

Various forming procedures can be used for metal spinning depending on the building material and the desired output volume. For thinner gauge materials and low-to medium-volume applications, the hand-shaped metal might be best achieved by a trained operator delicately pulling a roller. This procedure is known as manual spinning. In situations when higher pressures are necessary, such as when working with harder metals or larger gauge materials, hydraulic-assisted spinning provides the advantages and versatility of manual spinning.

Including cutting-edge gadgets. With computer numerical control (CNC) controls, metal spinning becomes faster, more precise, and more consistent. Complex geometries with strict tolerance requirements can be produced quickly, accurately, and reliably in medium to high production numbers.

Modern computer-assisted machining (CAM) software is used to program this equipment. Additionally, operators can use a "teach" mode, where the computer records the movements of manually spinning the initial component. You can automate manufacturing a huge volume of components once the initial workpiece is made by using replay mode, which precisely replicates the actions of the hand-spinning operation.

What Is Hydroforming?

One metal production method is sheet hydroforming, which involves using pre-shaped plates or dies and pressurised fluid to mould malleable metal into the desired components. Reduced wastage and guaranteed structurally durable parts and components result from hydroforming, a fast, efficient, and inexpensive metal-forming process. 

Hydroforming is superior to conventional stamping when shaping complicated, asymmetrical, or intricate components. Hydroforming is the way to go if you need to shape carbon or stainless steel, copper, aluminium, bronze, or brass.

Among the many uses for hydroforming are the aerospace and defence industry, the commercial food industry, medical equipment, satellite communications, and many more.

What Is Hydroforming In Manufacturing?

Although the displacement mechanism differs in hydroforming and metal spinning, the two processes have similarities. For example, a blank marginally bigger than the final product is utilised as the foundation.

As long as the corners are rounded, hydroforming can create polygons and workpieces with irregular shapes; a round shape is not necessary. While metal spinning allows for forming a broad array of ductile metals, hydroforming suits smaller gauge materials and more intricate part geometries.

Types Of Metal For Hydroforming

Copper, aluminium, carbon, nickel, stainless steel, and nearly all high-strength, high-temperature alloys can be hydroformed. This includes nearly all metals that can be cold-formed. Producing structurally solid components with diameters ranging from 1.0" to 30.0" and draw depths up to 12.0" is made possible by its expansive and versatile work envelope. The standard tolerances for aeroplanes, which are tight, are easily attained at ±.003".

A male dies and a draw ring, also known as a blank holder, make up the tooling used in sheet hydroforming. No fabrication is required because the hydroforming press's urethane rubber diaphragm serves as a universal female die.

Less complex tooling also allows for shorter lead times, and the process dynamics make it possible to modify the material thickness without changing the tool. Compared to traditional press tooling, hydroform tools often cost half as much, sometimes even less, than the latter.

Hydroforming Or Metal Spinning?

A wide range of sectors utilise superior manufacturing techniques, including hydroforming and metal spinning, to create essential parts and components. You should consider the details of your application carefully before deciding which of these methods to use because each has its own set of benefits.

Producing components of exceptional quality and performance is another application of metal spinning. The metal spinning technique allows for the rapid creation of components, typically within a few weeks, greatly reducing the time it takes to have parts and components ready for use. The metal spinning technique usually allows the most adaptability and efficiency for making parts and components. Metal spinning works with various metals, including carbon steel and aluminium. 

What Are The Benefits Of Hydroforming and Metal Spinning?

These techniques offer superior choices because of the relatively low tooling investment required for metal spinning and hydroforming compared to conventional deep drawing. Additionally, there is more leeway and setup times are reduced.

Hydroforming, in particular, is an area where these technologies may compete at bigger volumes. Many complicated, production-level components in the aerospace and automobile sectors employ it.

Metal spinning and sheet hydroforming are two manufacturing processes that have a lot of promise for prototypes and low to medium-volume production. This is a popular trend, especially for products with unique customisations, low demand, or a short life cycle due to changed consumer preferences.

Cheap, low-volume production also allows companies to break into untapped markets or carve out a unique niche in well-established ones. A corporation can test growth and expansion potential and product development plans in less-known markets by producing at a lower investment and volume, reducing risk and exposure.

Both metal spinning and hydroforming are extremely adaptable processes that find employment in various commercial, architectural, medical, transportation, and industrial settings. Both have the potential to enhance and add versatility to the production of a wide variety of components, and they can meet an almost endless diversity of design issues. 

The car industry is one sector keen on using lighter components to achieve fuel reduction goals and cut CO2 emissions. Automotive manufacturers must use innovative production techniques and strong, lightweight materials like aluminium to reduce vehicle weight and meet the increasing demands for optimal fuel efficiency, safety, and environmental regulations. Engineers can specify stronger and more resistant to environmental exposures to spun metal or hydroformed components, which are lighter than machined or stamped counterparts. 

Both of these production methods find application in the architectural sector for projects of varied sizes and degrees of complexity. Large quantities of cylindrical lighting components are available for commercial use. However, designers looking to add dramatic, one-of-a-kind lighting to a commercial project on a budget might benefit greatly from low-volume manufacture. Door knobs are just one example of an ordinary product that may have a personalised touch while still being functional and durable.

Spin and hydroforming are perfect for just-in-time delivery of a few units per order because technologically complicated equipment, such systems utilised in the medical business, is usually created in low volume numbers. The major benefits are avoiding the cost of long-term part inventories and making easy, low-cost design adjustments in response to technical developments.

Advantages Of Hydroforming

There are several advantages of hydroforming over more traditional processes, such as stamping, including:

Fast & Efficient

Hydroforming eliminates the need for further finishing processes and forms structurally sound, flawless components in approximately 20 seconds with a tolerance of +/- 0.003 inches.

Complex Shapes

Hydroforming is the way to go for parts with complicated or odd shapes.

Cost-Effective

Hydroforming is economical for small, medium, and big batches. The great adaptability of hydroforming to design modifications makes it a great material for prototyping.

Sustainable

When compared to metal stamping, hydroforming leaves almost no scrap.

Advantages Of Metal Spinning

The benefits of metal spinning for a flexible and efficient process include:

Design Flexibility

Metal spinning may be easily adjusted to meet the changing needs of product designs, providing maximum flexibility at all times.

Seamless, High-Quality

Components that demand exceptional strength and aesthetics might benefit from metal spinning, which creates seamless, long-lasting pieces devoid of seams or welds.

Lower-Cost Tooling

Metal spinning tools are usually 10% more expensive than equipment used in other forms of forming, such as stamping, casting, and forging.

Short-Lead Times

Significantly reduced turnaround times are made possible by the metal spinning process. We can have the tooling and spun components ready in weeks.

Hydroforming & Metal Spinning Applications 

Numerous sectors make use of metal spinning and hydroforming methods, such as:

Aerospace & Defense

components of aircraft, satellites

Commercial Food Equipment & Cookware

surface cookware, well-seasoned cookware

Architectural Design

lighting components,

Energy

energy equipment for solar, steam, and wind power, in addition to fuel cells

Industrial

Thermostats, HVAC, filters, and pressure vessels; OEM partner

Medical

medical imaging facilities, research tools

Oil & Agriculture

drilling for oil, pipelines

Vehicle Components

parts for hot rods, rims for wheels, and housings made of steel

Conclusion

Metal spinning and hydroforming are two specialised ways to shape metal that are used in many fields, such as to make gas tanks, lighting equipment, musical instruments, and satellite dishes. They work well and quickly to make high-quality metal parts and components that last a long time. Metal spinning is the process of shaping metal plates in ways that are similar to making clay pot sculptures. It can be done by hand or automatically with CNC lathes. It can be used to make any metal that can be bent, like aluminium, stainless steel, alloy steel, gold brass, and steel titanium Hastelloy.

Metal spinning can be done on superalloys like titanium and Inconel or ductile metals like aluminium, copper, brass, carbon steel, and stainless steel using a mandrel that has been made to fit the size and shape of the workpiece that will be spun. Depending on the building material and the amount that is wanted, different forming methods can be used. For smaller gauge materials and low to medium-volume jobs, manual spinning works best. Hydraulic-assisted spinning, on the other hand, has all the benefits and flexibility of manual spinning.

Hydroforming is a quick, easy, and cheap way to shape metal that cuts down on waste and makes sure that parts and pieces will last. It works better than regular stamping when shaping parts that are difficult, asymmetrical, or intricate. Hydroforming works well with thinner materials and parts with complicated shapes, which makes it a great choice for many businesses.

Hydroforming and metal spinning are two ways that parts and pieces are made and used in many different industries. With hydroforming, you can make physically solid parts with diameters from 1.0" to 30.0" and draw depths up to 12.0". Compared to standard deep drawing, it requires fewer tools, gives you more freedom, and takes less time to set up.

For example, metal spinning lets parts be made quickly—within a few weeks—which cuts down on the time it takes to get them ready to use. It can be used with many metals, such as aluminium and carbon steel. Both ways are good because they can make things quickly and efficiently, give you more design options, use cheaper tools, and cut down on wait times.

Hydroforming is very popular in the aerospace and auto industries because it can compete at higher volumes and meet the growing needs for safety, fuel economy, and environmental regulations. It can also be used for just-in-time delivery of a few units per order since high-tech items are usually only made in small quantities.

Hydroforming is better than standard methods in many ways, such as speed, efficiency, complexity, cost-effectiveness, and long-term use. Metal spinning gives you more design options, high-quality, seamless pieces, cheaper tools, and shorter wait times.

These methods are used in many fields, including architecture, commercial kitchenware and tools for food preparation, energy, industry, medicine, oil and agriculture, and vehicle parts.

Content Summary

• Metal spinning and hydroforming are specialised metal-forming techniques often overlooked by engineers.
• These processes are crucial in manufacturing various products, including gas cylinders, musical instruments, and satellite dishes.
• Both techniques are known for producing high-quality, durable metal parts.
• Hydroforming is noted for its efficiency and minimal waste production, making it suitable for creating complex components.
• Metal spinning, or spin forming, shapes metal discs into desired forms, similar to clay pottery techniques.
• It can be done manually or with CNC lathes, with the latter being preferred for smaller production volumes.
• This process allows the creation of items from ductile metals like aluminium, stainless steel, and brass.
• Metal spinning can be a cold or hot forming process, depending on the material requirements.
• In manufacturing, metal spinning involves using a mandrel to shape metal sheets into precise dimensions.
• Superalloys and ductile metals are excellent candidates for metal spinning, offering versatility in production.
• Various metals, including high-performance alloys, can be spun, enabling intricate designs and features.
• CNC controls in metal spinning ensure fast, precise, and consistent outcomes, suitable for medium to high production volumes.
• Hydroforming uses pressurised fluid to mould metal into components, offering reduced wastage and durable parts.
• It excels over traditional stamping for complex or asymmetrical shapes and is ideal for various metals.
• Hydroforming finds applications in aerospace, defence, and medical equipment, among other sectors.
• The process allows for the creation of parts with irregular shapes, expanding its utility in manufacturing intricate geometries.
• Metals suitable for hydroforming include copper, aluminium, and high-strength alloys, supporting a wide range of product designs.
• Hydroforming tooling is less complex and expensive compared to traditional press tooling, offering cost advantages.
• Choosing between hydroforming and metal spinning depends on the specific requirements and benefits of each process.
• Metal spinning offers quick production times and flexibility when working with different metals.
• Both techniques require lower tooling investments compared to conventional deep drawing, providing cost efficiency.
• Hydroforming is competitive for larger volumes, especially in the aerospace and automotive sectors.
• These processes support low to medium-volume production and are ideal for prototypes and customisations.
• Low-volume production enables companies to explore new markets or niches with reduced risk.
• Metal spinning and hydroforming are adaptable to a range of industries, including commercial, medical, and industrial.
• Automotive manufacturers utilise these methods for lightweight, strong components to meet fuel efficiency goals.
• In architecture, these processes support the creation of unique lighting components and durable, functional door knobs.
• Just-in-time delivery benefits from these techniques, especially for low-volume, high-tech medical equipment.
• Hydroforming offers fast and efficient production of structurally sound components with minimal finishing required.
• It allows for the creation of complex shapes and is cost-effective for various batch sizes.
• Hydroforming is more sustainable, producing almost no scrap compared to metal stamping.
• Metal spinning provides design flexibility, adapting easily to changes in product design.
• It produces seamless, high-quality components, ideal for parts requiring strength and aesthetics.
• The tooling cost for metal spinning is significantly lower than for other forming processes.
• Metal spinning ensures shorter lead times, facilitating quicker production cycles.
• These methods are utilised in aerospace, defence, commercial food equipment, and architectural design.
• They support the energy sector, including solar, steam, and wind power equipment manufacturing.
• Industrial applications include thermostats, HVAC systems, filters, and pressure vessels.
• The medical industry benefits from these techniques for imaging facilities and research tools.
• The oil and agriculture sectors use these processes for drilling and pipeline components.
• Automotive components, such as wheel rims and housings, are also produced using these methods.
• Engineers favour metal spinning and hydroforming for their ability to meet stringent tolerance requirements.
• The versatility of these processes allows for the production of a wide range of metal components.
• Cost efficiencies make metal spinning and hydroforming attractive for new product development.
• By reducing material waste, these processes contribute to sustainable manufacturing practices.
• The adaptability of metal spinning and hydroforming supports customisation and innovation in product design.
• These techniques are essential for the production of parts in high-demand sectors like aerospace and automotive.
• Hydroforming's ability to handle complex shapes opens up possibilities for innovative component design.
• Metal spinning's rapid prototyping capabilities enable quick testing and iteration of new product designs.
• Ultimately, metal spinning and hydroforming offer manufacturers flexible, efficient, and cost-effective metal-forming solutions.