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 rotationally symmetrical
shape 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

tf = to sin αo

For preformed cone

sin αo
tf = t1
sin β

(t1 = to sin β)

A/P Lee Kim Seng

The pre-requisite for flow turning is axial symmetry,
thus all conic sections 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 tubes, 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 disadvantages 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.
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.
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% (2α
α ≅ 30°°)
In general, semi-cone angle 12°° ≤ α ≤ 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 hardness,
yield stress & tensile strength, with a
concurrent reduction in elongation.

Metallurgical properties of the final part are better

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.

A/P Lee Kim Seng

 With the use of an
idealized model of flow
turning and assuming
simple shear
deformation under the
roller.

General power = Specific energy Volume

×
consumed Unit time
dV
i.e. P = u
dT
A/P Lee Kim Seng
 Energy
Specific energy, u =
Unit volume
γ = cot α
= ó τ dγγ ----- (1)
õ0

where τ = shear stress

dγγ = shear strain

Shear strain is the distance an element moves

axially divided by the thickness of the element
(γγ = cot α)
dx
i.e. = γ
dt
A/P Lee Kim Seng
 Assuming a Von Mises / Henky Yielding Criteria:

1
σ = σx - σy)2 + (σ
[(σ σy - σz)2 + (σ
σz - σx)2 + 6(ττxy2 + τyz2 + τzx2)] ½
√2

All stresses except τxy are zero

σ
∴ τ = ----- (2)
√3

A/P Lee Kim Seng

 The flow turning action will produce a shear strain of cot α
where α is one-half the total included angle
cot α
From Equation (1) u = ó τ dγγ
õ0

cot α
σ σ
∴
τ = ∴ u = ó dγγ ----- (3)
√3 õ0 √3

Assuming non-strain hardening, perfect plastic material σ = σo

1
∴ u = σo cot α ----- (4)
√3
A/P Lee Kim Seng
Alternatively, Specific energy = Area under σ / ε curve
ε
ó
õ σdε
u =
0

For simple shear

ε
cot α ∴ ó
õ σdε
u =
ε =
√3 0

cot α
For σ = σo = σo
√3
1
= σo cot α
√3
A/P Lee Kim Seng
 dV
π R to sin α f N
= 2π ----- (5)
dT

where f is measured parallel to the cone face

dV
∴ P = u P = Power
dT
dV ó ε
= σdε
dT õ
0

dV ó γ
or = τ dγγ
dT õ 0
A/P Lee Kim Seng
From Equations (4) & (5)

dV
∴ P = u
dT
cot α
π R to sin α f N σo
= 2π ----- (6)
√3

2
Power P = π N to R f σo cos α ----- (7)
√3
∴ .
P = Tθ
.
θ = 2π
πN
A/P Lee Kim Seng
 1
∴ Torque T = to R f σo cos α ----- (8)
√3

1
∴ Tangential force = to f σo cos α ----- (9)
√3

cot α
or = to f sin α σo
√3

óε σ d ε
õ
0

A/P Lee Kim Seng

In general ε
Tangential force = to f sin α ó
õ σdε
0
cot α ó ε cot α
For simple shear, ε =
õ σ d ε = σ o √3
, thus
√3 0
i.e. σ = σo
Torque = Tangential force × radius
ε
= to f R sin α ó
õ σdε
0

Power = Torque × 2π
πN
ε
π N to f R sin α ó
õ σdε
= 2π
0
A/P Lee Kim Seng
NOTE :

The effective strain consider above does not

include any redundant straining and is solely on
simple shear.

A/P Lee Kim Seng

In practice, the loads may often be much greater than
those predicted, due to constraint imposed by the
necessity for the metal to flow in a particular way.

In general, the more curve the shear lines, the higher

the pressure required to make the metal flow.

The work done in overcoming this excess constraint

cannot be found from the overall change in shape,
and is known as redundant work.

Surface stress analysis takes no account of redundant

work, and there is in fact no general analytical theory.

A/P Lee Kim Seng