Manufacturing Processes

Course code: 18PC1ME09

Year & Sem: III B.Tech-Sem1
Academic year: 2020_21

Unit 5- Mechanical Working2

Topic:
5.3 & 5.4.- Stretch Forming & Spinning

Prepared by:
A N Brahmeswara Rao,
Sr. Asst. Professor- MED, VNRVJIET

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 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.3- Stretch Forming (forming): (FMM, Groover, ch.20.6.1), (MT, Rajput, Ch.3.9.4), (MT1, PNRao, Ch.
• Stretch forming is a method of producing contours in sheet metal.
• Stretch forming is a process in which the sheet metal is stretched and simultaneously bent to get
the desired shape or contour.
Forming is of two types: 1) Stretch forming 2) Stretch wrap forming

5.3.1. Stretch Forming Process:

the workpart is gripped by jaws on each end and then stretched and bent over a positive die
containing the desired form.
• The metal is stressed in tension to beyond its yield point to deform plastically.
• The combination of stretching and bending results in relatively little spring back in the part.
 

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 2

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.3.2. In stretch wrap forming, the sheet is first gripped and stretched beyond yield point
(while it is straight) and then wrapped around a form block (die) where the die is fixed and
the sheet is moving.

Forces in stretch forming:

F= W t Yf where F - stretching force (N)
W - width of the sheet (perpendicular to stretching) (mm)
t - instantaneous thickness of sheet (mm)
Yf - flow stress of the work metal (MPa)
 The die force Fdie can be determined by balancing the vertical force component.
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A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 3

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.4.- Coining: (refer to 5.2)
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5.5. Spinning (Hot & Cold Spinning):
• Spinning is a metal forming process in which an axially symmetric part is gradually shaped over a
mandrel or form by means of a rounded tool or roller.
 The tool or roller applies a very localized pressure (almost a point contact) to deform the work by
axial and radial motions over the surface of the part.

Application: Basic geometric shapes produced by spinning are cups, cones, hemispheres, and tubes.

Types of Spinning: There are three types of spinning operations:

(1) Conventional spinning, (2) shear spinning, and (3) tube spinning.

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 4

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.5.1. Conventional Spinning or spinning:
 in this, usually, a sheet-metal disk is held against the end of a rotating mandrel of the desired
shape, as shown in the fig. above. (in some cases other than a flat disk is used)
 the thickness of the part remains same before and after the process
 A tool is used to control the position and shape the metal against the mandrel.
• The tool can be hand operated, machine operated or automatic such as CNC.
a) Hand spinning: tool is positioned and controlled by hand
b) Power spinning: tool is positioned and controlled by machine or automatically. It is used for
higher forces, faster processing, and better control of the process.

Applications: conical and curved shapes in low quantities and large diameter parts up to 5m.
 

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 5

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.5.2. Shear spinning: (Also called Flow turning, Shear forming and Spin forging):
• In shear spinning, the part is formed over the mandrel by a shear deformation process.
• The wall thickness is reduced and the outside diameter remains uniform.
 This shear straining and consequent thinning of the metal, distinguishes this process from the
bending action in conventional spinning, to form large parts such as rocket nose cones.
 The input work piece is a flat disc.

Application: Aerospace industry to form large parts such as rocket nose cones

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 6

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.5.3. Tube spinning:
• Tube spinning is used to reduce the wall thickness and increase the length of a tube by means of a
roller tool applied to the work over a cylindrical mandrel
• The operation can be performed by applying the roller against the work externally (using a ylindrical
mandrel on the inside of the tube) or internally (using a die to surround the tube).
• It is also possible to form profiles in the walls of the cylinder, as in Figure 20.44(c), by controlling the
path of the roller as it moves tangentially along the wall.

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 7

 Unit-5: Mechanical Working 2- Stretch Forming & Spinning
5.5.4. Hot spinning: (MT1, PNRao, Ch.8.6) (Spinning, Wikipedia)
• Hot spinning is same as spinning with the work piece in hot condition.
• "Hot spinning" involves spinning a heated metal part or, spinning while heating on a lathe with the
help of a torch, using mechanical (power) tools.

 Once heated, the metal is then shaped as the tool on the lathe presses against the heated surface
forcing it to distort as it spins.
 Parts can then be shaped or necked down to a smaller diameter with little force exerted, providing
a seamless shoulder.

Application:
- Thick dished pressure vessels, tank shapes.
- Also used for thin metal sheets of high toughness or hardness such as titanium.

A N Brahmeswara Rao, Sr. Asst. Professor- MED, VNRVJIET 8

Thank you