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ABSTRACT
This paper presents improvement in manual metal spinning process. The machine carriage is modified mainly for the purpose
of reduction in requirement of a skilled workforce. The spinning machine consists of a mandrel mounted onto the headstock
spindle. A work piece on which operation is to be performed is clamped in between this mandrel and the tailstock (dead centre).
Final component formed by pressing blank over the mandrel. The operation is performed by a hand tool on a spinning lathe. It
is tedious process. Lots of human effort required for this process. The metal spinning machine with lathe carriage is a
modification of the manual machine. By using roller tool & lathe carriage aids to control the entire operation, in order to
reduce requirement of skilled labour, to improve overall efficiency in the current process, improving consistence and
repetitiveness along with an overall reduction in cost. Also in this we find out effect of roller tool radius on surface finish of
final component. For trial purpose we design various roller tools & make modification in lathe carriage.
Keywords: Spinning, Roller, Mandrel, Blank.
1. INTRODUCTION
Metal spinning is one of the oldest method of chip-less formation. Metal spinning is a term used to describe the
forming of metal into seamless, axisymmetric shapes by a combination of rotational motion and force. Metal spinning
is the technique to produce axisymmetrical part or component over rotating mandrel with the help of rigid tool known
as roller. During the process both the mandrel and blank rotated while the spinning tool contract the blank and
progressively induce a change according to the profile of the mandrel. Spinning process helps to produce a lightweight
component. The components of metal spinning are cylinders, drums, Domes, hemispheres, cones, cups etc.
Alternatives to spinning such as press forming are also used for the production of axisymmetric sheet metal
components. However, spinning has a number of advantages when compared with these manufacturing methods.
Localised deformation of the material under the roller requires low forming forces. Moreover, simple and non-
dedicated tooling provides flexibility and has the potential for net shape forming. Lastly, formed components have high
quality surface finish and improved strength.
Figure 2 Tools
The primary tools are the Sheep's nose used for most of the forming, and the Duck's bill used for finishing the fully
formed piece. The hooked nose of the Sheep's nose is ideal for forming tight radii as well as having a decreasing radius
that makes it easy to form the metal over a variety of curves. The Duck's bill has a flat side for finishing straight
surfaces and a rounded side to finish curved surfaces. The tool post is essentially a rounded pin protruding from a
boring bar mounted on the crossfeed such that the pin acts as a fulcrum around which the hand tool can be leveraged.
The tool post is moved as the part forms down the mandrel so that a consistent lever arm is maintained.
measured in mm/sec or mm/ min. Due to the high feed rate rough surface finish & wrinkling may be occur. A low feed
rate gives a high surface finish while a high or increased feed rate will make a work piece fit to mandrel. Due to high
feed rate rough surface finish and wrinkling occurs this is the main drawback of high feed rate.
c) Spindle Speed[2]
According to hayama the effect of mandrel speed on to the tool forces is very less, almost negligible. Due to this
negligence a wider range of feasible mandrel speed is possible. The influence of rotational speed on the variation of
axial and radial forces is negligible. For aluminium material we take Spindle speed 800 to 900 rpm. On an average, the
best quality of most of the components is achieved at high spindle speeds.
N= (9500~320000)/Do
Where,
N=Mandrel speed in RPM
Do= original blank diameter in mm
N=270000/300=900 rpm
d) Lubricants[5]
A lubricant is used for providing lubrication between two surfaces under friction which produces an immense amount
of heat. A lubricant is almost always used during spinning. The fluid used serves as both a lubricant and coolant.
.When spinning aluminium, stainless steel or titanium, the work pieces or mandrels or both are sometimes coated with
the lubricant before spinning. The lubricant must continue to adhere to the rotating preform during spinning. Most of
the time cup grease is used. Viscosity is an important parameter of a lubricant. To reduce the viscosity, a lubricant can
be heated. Reduced viscosity helps in easy application of the lubricant.
In the figure below we can see mandrel, chuck, tailstock live centre and tailstock. The mandrel is held in the chuck and
tailstock live centre is held in the tailstock. The use of chuck is to rotate the mandrel with certain speed & tailstock live
centre support the mandrel. Tool posts are used to hold the tool & travel the tool in direction of workpiece. Roller is the
tool which is contact with the workpiece and it is held in tool post. The blank is clamp between mandrel male and live
centre female part. When spindle speed is given to mandrel then mandrel and blank start rotating together along with
live centre at high speed. The roller is then passed on the blank and in turn forces are generated on the sheet of
workpiece. This flows over the mandrel and obtains the same shape as that of the mandrel.
4. RESULT
By making the modification in the setup we take a trial and produce final component without any crack and wrinkle.
The final component is shown in Figure 6.
5. CONCLUSION
In conventional process the worker had to apply a lot of force while in process with carriage, workers efforts are
reduced and a very less force is to be applied. Also using above design parameters we have to reduce the defect &
failure occurs in metal spinning operation performed with lathe carriage. The accuracy of the process also increases
considerably with using the new process with carriage. Using large nose radius provides high surface quality. If a good
machine is available then the working time is also reduced highly. Skilled worker can produce components or final
products with very good surface finish and high accuracy. If the carriage movement and tool movement is automated
then a very perfectly precise product can be obtained.
Acknowledgements
We thank Mr. Bandekar (Proprietor- Laxmi metal industry, Kudal MIDC) for providing us with this opportunity to
work in the development of this machine. We also thank employee Mr. Lad for sharing with us his valuable
knowledge and experience. We also would like to thank our guide Pr. M.T. Sawant for his constant support and
encouragement. Lastly, we thank all those who have directly or indirectly helped us in the development of this
machine.
References
B.P.Bewlay, Spinning, ASM Handbook, volume 14B, pp.367-374
J.M Allwood, A review of mechanics of metal spinning, Journal of Material Processing Technology 210(2010),
pp.3-23
Wang Lin, Analysis of material deformation and wrinkling failure in conventional metal spinning, Durhan
University (2012), pp.1-182
C.C.Wong, A review of spinning, shear forming and flow forming processes, International journal of Machine tool
& Manufacture 43(2003), pp.1419-1435
Amol Jadhav, Design of metal spinning parameter for general lathe, International journal of Engineering
Development & Research(2014), pp.3194-3200
AUTHOR
Mandar Sawant completed the B.E. degree from Rajendra Mane College of Engineering and Technology and
completed M.E. degree in CAD/CAM/CAE from KIT College.