Metal spinning

An industrial manufacturing process with a tradition of craftsmanship.

Metal spinning is a non-cutting, cold forming process in which mostly circular discs (rondelles) are "driven" onto a mold (tool) by rotation and the targeted application of force via rollers and rods. If metal spinning is carried out by a specialist, hardly any other forming process can match the cost-effectiveness of metal spinning - especially for individual parts or small series! Take advantage of the possibilities of this interesting process. 

The advantages of metal spinning: 

• Low tooling costs
• Simple (inexpensive) starting material
•  Various materials
• Achievement of desired material properties
• High-quality components

Metal spinning process description

The origin of metal spinning lies in the forging of metal. Cold forming, combined with a metallic flow process (similar to wheel-throwing with clay), allows material properties to be achieved that can be of great benefit to the function and area of application of the finished component.

Metal spinning, like deep drawing, is a non-cutting shaping process. In addition to traditional manual spinning, hydraulic and CNC replay technology is also used. The starting material is usually round, flat sheet metal discs, known as blanks. These are pressed around a wooden or steel mold, the spinning mold, using spinning rollers or spinning rods. In the case of rotationally symmetrical hollow bodies, this mold rotates. In most cases, the rotating tool has the inner contour of the product to be manufactured and the counter-pressure is only applied locally. Finishing of the workpiece includes finishing, calibrating, beading, rebating, edging, drawing-in and trimming.

We have developed special 8-axis-controlled trimming machines for these operations. This allows these operations to be automated, reproducible and economically optimized.

Precisely fitting parts with exceptional material properties

Craftsmanship, a wealth of experience, metallurgical knowledge and the right machines. These are the most important ingredients for high-quality and economical components.

The video opposite shows impressively how a finished component is created from a simple sheet metal disc (roundel) with a great "feel" for the material and the processes. This requires years of experience and craftsmanship, be it in manual spinning or in creating the programs for CNC-controlled metal spinning.

Inspiring solutions - metal spinning: 

Video examples - Metal spinning:

Metal spinning - an extremely sustainable manufacturing process

Overall, metal spinning is a sustainable manufacturing method as it contributes to the efficient use of resources, reduced waste, lower emissions and higher recycling rates.

1. Resource efficiency: In metal spinning, the material is formed into a specific shape without any loss of material. This means that raw materials are used efficiently and less waste is produced.
   
   
2. Recyclability: Metals can be recycled endlessly without compromising the quality of the material. Metal spinning helps to ensure that metal waste can be returned to recycling facilities. The recycling of metals helps to reduce the environmental impact by reducing the need for new raw materials.
   
   
3. Energy efficiency: Compared to other manufacturing processes, metal spinning requires less energy to produce the same quantity of metal parts. This results in lower emissions and lower energy costs.
   
   
4. Durability: Metal parts produced by metal spinning are often more durable than those produced by other manufacturing processes. This means that the parts need to be replaced less frequently, reducing resource consumption and waste.
   
   
5. Recycling rate: Metal spinning helps to increase the recycling rate of metals. The recycling rate of metal products is usually around 95%, which means that almost all of the metal can be reused in new products.

Design guidelines for metal backs

Tolerances:

The general tolerances should be roughly applied.

Smaller tolerances can be adhered to in some cases.

Dimensions:

Materials:

All metals suitable for spinning in a tabular overview:

Download as PDF

Design features and their influence on forming/costs:

Teileverrundung, Eckradius, Bodenradius

Der innere Bodenradius R sollte im Minimum zwischen 1 x bis 2 x die Blechdicke sein.

Dadurch verbessern sich die Fliesseigenschaften in der Umformung und das Bauteil kann kostengünstiger  hergestellt werden.

 Umformgrad 1, Teilehöhe

Durch die Verkürzung der Bauteilhöhe, braucht es weniger Aufwand in der Umformung. Dadurch reduzieren sich die  Stück- wie auch die Werkzeugkosten.

Wird eine grosse Bauteilhöhe verlangt, so ist die Metallumformung immer die kostengünstigste Variante.

Umformgrad 2, Flanschbreite

Durch die Verkleinerung des Bauteilrandes, braucht es weniger Aufwand in der Umformung. Dadurch reduzieren sich die Stück- wie auch die Werkzeugkosten.

Wird ein breiter Rand verlangt, so ist die Metallumformung immer die kostengünstigste Variante.

Hinterschnitt

Für eine einfache und kostengünstige Herstellung muss das Bauteil vom Werkzeug entformbar sein. Das heisst, dass Hinterschnitte nur in separaten Operationen hergestellt werden (Sicken, Bördeln) können.

Das Bauteil muss  rotationssymmetrisch und vom  Werkzeug entformbar sein.

Grundfläche

Beim Metalldrücken sind nur runde, rotations-symmetrische Teile herstellbar.

Wird eine andere Grundfläche benötigt, muss das Bauteil mit dem Verfahren Tiefziehen hergestellt werden.

Bodenform

Die Bodenverformung sollte auf das Minimum reduziert werden. Die ideale Form ist ein U mit grosszügigem Bodenradius.

Mit einem kleinen Mehraufwand sind auch andere  Bodenformen herstellbar (Hohlkugel, Halbkugel).

Mantelfläche

Beim Metalldrücken gibt es in der Mantelform keine Einschränkungen, ausser dass das Bauteil rotationssymmetrisch und entformbar sein muss.

Bordierungen, Randgeometrie

Flansche und Bordierungen sind nach Möglichkeit nach  Aussen zu legen. Flansche und Bordierungen  nach Innen  sind mit Mehraufwand herstellbar.

Wenn Bordierungen nach Innen benötigt werden, so ist häufig die Metallumformung  anderen Verfahren überlegen (Schweissen, Montage...).