How Technology and Innovation has Impacted Metal Spinning
As Frank Crawshaw points out in his book Metal Spinning written in 1909, “It is believed that some quarters, particularly among metal spinners, that pressing or stamping metal can never fully take the place of spinning it. It is impossible to press or stamp some forms except as they are produced in parts and these parts soldered, brazed or riveted together.” (Crawshaw 9) Indeed, metal spinning is an age-old craft that is as much an art as it is a science. Metal spinning has quite the history, and truly has stood the test of time. Before the introduction of the lathe, craftsmen had to rotate their workpiece manually and apply the spinning tool by hand, limiting the complexity and tolerances of their final shapes. It’s believed that the potter’s wheel was the inspiration behind the hand powered lathes used in the earliest examples of metal spinning, while some say manual lathes consisted of two people and a rope-wound spindle.
The metal spinning process originates back to ancient civilizations, with evidence finding that it was first used during the times of the ancient Egyptians, where craftsmen used lathes to shape soft metals, such as bronze, copper, silver and gold. The process was manually demanding and required a high level of skill to achieve precision, yet it allowed for the creation of objects with minimal material waste. Metal spinning in its early era showcased a clear reflection of an emerging awareness of efficient material use.
In the Middle Ages, the hand-powered lathe was replaced by a foot-powered lathe, equipped with a pedal to free the craftsmen’s hands to make more detailed items. The peddle enabled for continuous rotation and increased efficiency.
By the 19th century during the Industrial Revolution, there was an increase in the push for automation, which directly impacted metal spinning. Spinning lathes evolved to be much less manual and more automated, by making them steam-powered. This allowed for the forming of much thicker materials into components for firearms, scientific tools, and even instruments. With these developments came requirements of upgrading tooling. Engineers recognized that with higher speeds, pressures, and the repeatability factor, a more durable material was needed for tooling.
In the early 20th century, hydraulic lathes brought even higher speeds and increased consistency, shaping metal spinning into the modern processes that we use today. Then came the incorporation of computer numerical control. CNC re-shaped the industry and allowed for an exceptional level of precision and repeatability, while providing efficiency and streamlining the manufacturing process. CNC technology that allows us to develop highly accurate programs for each specific part, ensuring precision and consistency with every piece produced.
CNC metal spinning, also known as spin forming, is a highly effective process of shaping sheet metal into a variety of forms. Utilizing a lathe and CNC controls, a metal disc is rotated and pressed against a tool by a tailstock. A spinning roller then presses against the metal in a circular motion, and a roller manipulated with CNC controls, presses against the metal to form the metal over the tool through a series of passes by the roller. This process results in a final product that precisely mirrors the shape of the tool used to form it.
Metal spinning is particularly effective for forming basic shapes such as cones, flanged covers, hemispheres, cylindrical shells, venturis, and parabolic nose shapes.
Material innovation
As mentioned above, tool steels have become much more dense and durable over time, where they are able to be used with high-speed lathes, high pressures of the materials being formed, can handle the forming of thicker materials and larger pieces. While common materials such as mild steel and aluminum are still frequently used, metallurgical advancements have opened the door to the use of high-strength alloys with high corrosion resistance and extreme durability. Working with tough metals broadens what’s possible to form on the lathe – especially for parts used in extreme environments.
Technological Opportunities
There is a myth that metal spinning is outdated, and an old art. While it is a very old process, it has evolved with technological innovations, and is considered a widely used process throughout the world, impacting many different industries. Metal spinning is a cost-effective process, produces minimal waste,
Because of artificial intelligence and machine learning, metal spinning has been given the opportunity to make further technological advancements by optimizing production processes and increase problem or complication predictions. With artificial intelligence, large amounts of operational data can be analyzed in very short timeframes, and operators and manufacturers will be able to fine-tune their processes quicker than ever before. This will result in next level efficiency, with even less waste.
Virtual learning, simulation software, and virtual-reality software is also a new landscape for learning and training. Creating virtual prototypes and processes enables the user to learn by making mistakes, without making a mistake in real-time, or using up real materials. This opens up the ability to recognize stress points and issues with material flow before placing a blank on the lathe, resulting in even more precise and high-quality final products. As technology continues to develop, so will the art of metal spinning.