Metal spinning, Explosive forming

& Magnetic pulse forming

 Metal spinning
• Metal spinning, also known as spin forming or spinning
or metal turning most commonly, is a metal working
process by which a disc or tube of metal is rotated at
high speed and formed into an axially symmetric part.
Spinning can be performed by hand or by a CNC
machine. This process is used to produce architectural
detail, specialty lighting, decorative household goods.
Virtually any ductile metal may be formed, from
aluminum or stainless steel, to high-strength, high-
temperature alloys. The diameter and depth of formed
parts are limited only by the size of the equipment
available.
Metal spinning
Spinning
Metal spinning
Metal spinning
Metal spinning
 Explosive forming
• Explosive forming is a metalworking technique
in which an explosive charge is used instead of
a punch or press. It can be used on materials
for which a press setup would be prohibitively
large or require an unreasonably high
pressure, and is generally much cheaper than
building a large enough and sufficiently high-
pressure press; on the other hand, it is
unavoidably a batch process, producing one
product at a time and with a long setup time.
 Explosive forming
• The process has been successfully used to
form steel plates 25 mm thick x 4 m diameter
and to bulge steel tubes as thick as 25 mm.
Explosive Forming
• Standoff Method
In this method, the explosive charge is located at some
predetermined distance from the workpiece and the energy is
transmitted through an intervening medium like air, oil, or water.
Peak pressure at the workpiece may range from a few thousand psi
to several hundred thousand psi depending on the parameters of
the operation.
• Contact Method
In this method, the explosive charge is held in direct contact with
the workpiece while the detonation is initiated. The detonation
produces interface pressures on the surface of the metal up to
several million psi (35000 MPa).
Explosive forming
Explosive forming
Explosive Forming
 Advantages of Explosion Forming

• Maintains precise tolerances

• Eliminates costly welds.
• Controls smoothness of contours.
• Reduces tooling costs.
• Less expensive alternative to super-plastic
forming.
 Material of Die

Material of Die Application Area

• Concrete - Low pressure and large parts
• Epoxy and Concrete - Low pressure and large parts
• Ductile Iron - High pressure and many parts
• Concrete - Medium pressure and large parts
The nozzle of the space shuttle main
engine (before and after explosion)
Prototype part of an Airbus fuselage,
created by explosive forming ( R & D)
 Magnetic Pulse Forming
Basic operation,
1. A large current discharge is directed through a coil. The
coil has been placed inside another shape.

2. The discharging current creates a magnetic field. In the

nearby sheet of metal an opposing magnetic field is
induced. The result is that the two magnetic fields
oppose and a force moves the sheet away from the
coil.

3. Over a period of time the part is deformed, often to

the shape of a mandrel, or other form.
 Magnetic Pulse Forming
• Magnetic pulse forming is a process, where very high energy is
stored into a capacitor bank and delivered into the job precisely at
forming location. Very short period pulse will deliver Megawatts of
energy into the job. Even with this enormous power input, heating
of the job is negligible. The maximum energy is being utilized for
forming or welding.
The heavy current flow in the magnetic coil generates stronger
magnetic fields, which in turn generate circular currents in the
outer shell which will collapse into inside shell at supersonic speeds,
and forms a joint with the inner shell. The actual process is of less
than a millisecond process. It needs no external fluxes or filler
material. Different materials can be welded together. The entire
operation is a cold process; hence no heat affected zone is created.
The process is suitable for all conducting materials.
 Magnetic Pulse Forming
• Advantages,
- easy to control
- allows forming of metals to any material
- no contact eliminates many requirements such
as lubricants, eat dissipation, surface pair, etc.
- no tool wear
- minimal operator skill
- energy efficient
- easy installation
- high production rates (typically a few seconds)
Magnetic Pulse Forming
Magnetic Pulse Forming
Magnetic Pulse Forming
 Applications

• The forming process is most often used to shrink or

expand cylindrical tubing, but it can also form sheet
metal by repelling the work piece onto a shaped die at
a high velocity. High-quality joints can be formed,
either by electromagnetic pulse crimping with a
mechanical interlock or by electromagnetic pulse
welding with a true metallurgical weld. Since the
forming operation involves high acceleration and
deceleration, mass of the work piece plays a critical
role during the forming process. The process works
best with good electrical conductors such as copper
or aluminum, but it can be adapted to work with
poorer conductors such as steel.
 Annexure- II
Questions
1) List some components produced by metal spinning
process.
2) Compare metal spinning with explosive forming
process.
3) What are all the advantages of metal spinning
processes?
4) What are the characteristics of the material
processed in magnetic Pulse Forming?
 Annexure- III
Key Words
1) Embossing - Process for producing raised or
sunken designs or relief in sheet metal
2) Swaging - A forging process in which the
dimensions of an item are altered using a die
Annexure- IV Mind map
 Annexure-V Summary
Metal spinning
Metal spinning, also known as spin forming or spinning or
metal turning most commonly, is a metal working process by
which a disc or tube of metal is rotated at high speed and
formed into an axially symmetric part.

Explosive forming
Explosive forming is a metalworking technique in which an
explosive charge is used instead of a punch or press. It can be
used on materials for which a press setup would be
prohibitively large or require an unreasonably high pressure,
and is generally much cheaper than building a large enough
and sufficiently high-pressure press;
 Annexure-V Summary
Magnetic Pulse Forming
In this process electric energy is converted into
useful work. Energy stored in the capacitor bank
is discharged rapidly through a magnetic coil. The
discharging current creates a magnetic field in the
nearby sheet of metal an opposing magnetic field
is induced. The result is that the two magnetic
fields oppose and a force moves the sheet away
from the coil. Over a period of time the part is
deformed, often to the shape of a mandrel, or
other form.
 Annexure – VI MCQ
1) The equipment generally used for metal spinning is
a) mechanical press b) hydraulic press
c) hammer d) lathe
2) Mass production of cooking utensils is done by
a) metal spinning b) deep drawing
c) coining d) embossing
3) The energy used In magnetic pulse forming is
a) heat energy b) electrical energy
c) a & b d) non of the above