Spinning

Spinning process
Spinning is the process used for making cup shaped articles which is axisymmetrical. The process of spinning consists of rotating the blank, fixed against the form block and then applying a gradually moving force on the blank so that , the blank takes the shape of the form blank. A typical set up is shown in fig. The setup essentially consist of a machine similar to a centre lathe. In the head stock of the spinning machine a hard wood form block which has the shape of the desired part is fixed . The blank is held against the form block by means of the freely rotating wooden block from the tail stock. After proper clamping , the blank is rotated to its operating speed. The spinning speed is depends on the blank material, thickness and complexity of the desire cup. Then the hard wood or roller type metallic tool is pressed and moved gradually on the blank so that it conforms to the shape of he form block. The manipulation of spinning tool s is a highly skilled art. The tool is to be moved back and forth on the blank so that no thinning takes place anywhere on the blank.

Spinning process
Spinning is comparable to drawing for making cylindrical shaped part. Because of the simple tools used in spinning, it is economical for smaller lots. But the time required for making a cup is more in spinning and also more skill is required in the process. Thus it is not suitable for large scale production. Complicated shape and re-entrant shapes are not feasible by drawing. But can be made by spinning using the sectional and collapsible form blocks. Large parts are much more easily made in spinning than by drawing. When sheet thickness is more , for example , in making the dished end of the pressure vessels cold spinning is not sufficient. Then the block is heated to the forging temperature and so the process is called hot spinning. Also in hot spinning the tools are mechanically manipulated because of he higher magnitudes of forces required.

Embossing and coining

Embossing
Embossing is the operation used in making raised figures on sheets with its corresponding relief on the other side. The process essentially involves drawing and bending of the metal. An example of the embossing operation is shown in the figure. A die set essentially consists of die and punch with a desire contours, so that when the punch and die meet the clearance between them is the same as that of the sheet thickness. Embossing operation is generally used for providing dimples on sheets to increase their rigidity and for decorative sheet work used for panels in houses and religious places.

coining
Coining is essentially cold forging operation except for the fact that the flow of the metal occurs only at the top layers and not the entire volume. The coining die consist of punch and die which are engraved with necessary details required on both sides of the final object. A blank kept on the die is compressed by it is shown in the fig the pressure involved in coining is very high of the order of 1600 Mpa because of the very fine details that are normally desired in coining. The type of impression obtained on both sides would be different unlike the embossing . Coining is used for making coins, medals and similar articles, and impression on decorative items.

Rubber forming process

Hydro forming process

Rubber forming process

RUBBER FORMING PROCESSES The two operations discussed in this article are performed on conventional presses, but the tooling is unusual in that it uses a flexible element (made of rubber or similar material) to effect the forming operation. The operations are (1) the Guerin process, and 2) Hydro forming Guerin Process The Guerin process uses a thick rubber pad (or other flexible material) to form sheet metal over a positive form block, as in Figure 20.28. The rubber pad is confined in a steel container. As the ram descends, the rubber gradually surrounds the sheet, applying pressure to deform it to the shape of the form block. It is limited to relatively.

Rubber forming process

shallow forms, because the pressures developed by the rubber up to 10 M Pa (1500 lb/in2)are not sufficient to prevent wrinkling in deeper formed parts. T he advantage of the Guerin process is The relatively low cost of the tooling. The form block can be made of wood, plastic, or other materials that are easy to shape, and the rubber pad can be used with different form blocks. factors make rubber forming attractive in small-quantity production, such as the aircraft industry, where developed.

Hydro forming process

Hydro forming Hydro forming is similar to the Guerin process; the difference is that it Substitutes a fluid in place of the thick rubber pad, as in Figure 20.29. This allows the pressure that forms the work part to be increasedto around 100 MPa (15,000 lb/in2)thus preventing wrinkling in deep formed parts. In fact, deeper draws can be achieved with the hydro form process than with deep drawing. This is because the uniform pressure in hydro forming forces the work to contact the punch throughout its length, thus increasing friction and reducing the tensile stresses that cause tearing at the base of the drawn cup.