UNIT:1

Roll forming
INTRODUCTION

A variety of cross-section profiles can be produced, but each profile requires a carefully crafted
set of roll tools. Design of the rolls starts with a flower pattern, which is the sequence of profile
cross-sections, one profile for each stand of rolls. The roll contours are then derived from the
flower pattern profiles. Because of the high cost of the roll sets, computer simulation is often
used to develop or validate the roll designs and optimize the forming process to minimize the
number of stands and material stresses in the final product.

Roll formed sections may have advantages over extrusions of a similar shapes. Roll formed parts
may be much lighter, with thinner walls possible than in the extrusion process, and stronger,
having been work hardened in a cold state. Parts can be made having a finish or already painted.
In addition, the roll forming process is more rapid and takes less energy than extrusion.

Roll forming machines are available that produce shapes of different sizes and material
thicknesses using the same rolls. Variations in size are achieved by making the distances
between the rolls variable by manual adjustment or computerized controls, allowing for rapid
changeover. These specialized mills are prevalent in the light gauge framing industry where
metal studs and tracks of standardized profiles and thicknesses are used. For example a single
mill may be able to produce metal studs of different web (e.g. 3-5/8" to 14"), flange (e.g. 1-3/8"
to 2-1/2") and lip (e.g. 3/8" to 5/8") dimensions, from different gauges (e.g. 20 to 12 GA) of
galvanized steel sheet.

Roll forming lines can be set up with multiple configurations to punch and cut off parts in a
continuous operation. For cutting a part to length, the lines can be set up to use a pre-cut die
where a single blank runs through the roll mill, or a post-cut die where the profile is cutoff after
the roll forming process. Features may be added in a hole, notch, embossment, or shear form by
punching in a roll forming line. These part features can be done in a pre-punch application
(before roll forming starts), in a mid-line punching application (in the middle of a roll forming
line/process) or a post punching application (after roll forming is done). Some roll forming lines
incorporate only one of the above punch or cutoff applications, others incorporate some or all of
the applications in one line.
 Cluster roll set

Process

The process of roll forming is one of the simpler manufacturing processes. It typically begins
with a large coil of sheet metal, between 1 inch (2.5 cm) and 20 inches (51 cm). in width, and
0.004 inches (0.10 mm) and 0.125 inches (3.2 mm) thick, supported on an uncoiler. The strip is
fed through an entry guide to properly align the material as it passes through the rolls of the mill,
each set of rolls forming a bend until the material reaches its desired shape. Roll sets are
typically mounted one over the other on a pair of horizontal parallel shafts supported by a
stand(s). Side rolls and cluster rolls may also be used to provide greater precision and flexibility
and to limit stresses on the material. The shaped strips can be cut to length ahead of a roll
forming mill, between mills, or at the end of the roll forming line.

Geometric Possibilities

The geometric possibilities can be very broad and even include enclosed shapes so long as it is
the same cross-section throughout. Typical sheeting thicknesses range from 0.004 inches
(0.10 mm) to 0.125 inches (3.2 mm), but they can exceed that. Length is almost unaffected by
the rolling process. The part widths typically are not smaller than 1 inch (2.5 cm) however they
can exceed 20 inches (51 cm). The primary limitation is profile depth, which is generally limited
to less than 4 inches (10 cm) and rarely larger than 6 inches (15 cm) due to roll-imparted stresses
and surface speed differentials that increase with depth.

Tolerances can typically be held within 0.015 inches (0.38 mm) for the width of the
cross-sectional form, and 0.060 inches (1.5 mm) for its depth.[1]

Production Rates

The production rate depends greatly on the material thickness and the bend radius, it is also
affected by the number of stations or steps required. For bend radii of 50 times the material
thickness of a low carbon steel 0.7 inches (1.8 cm) thick can range from 85 feet per minute
(26 m/min) through eight stations to 55 feet per minute (17 m/min) through 12 stations or 50 feet
per minute (15 m/min) through 22 stations.
The time taken for one product to take shape can be represented by a simple function. The
function is as follows: where V is the velocity of strip
through rolls (fpm), L is the length of the piece being rolled (ft), d is the distance between
forming stands (ft), and n is the number of forming stands.[1]

In general roll forming lines can run from 5 feet per minute (1.5 m/min) to 500 + depending on
the application. In some cases the limiting factor is the punching or cutoff applications.

Other Considerations

While dealing with manufacturing, there are always things to be considered such as lubrication,
the effect of the process on material properties, cost, and of course safety.
Lubrication provides an essential barrier between the roll dies and the workpiece surface. They
help to reduce the tool wear, and allow things to move along faster. This table shows the
different kinds of lubricants, their application, and the ideal metals to use them on.

Work Material Roll Lubricants Application

Nonferrous Chlorinated oils or waxes, mineral oils Spray, wiping roller
Ferrous Water-soluble oils Wiping, drip, spray
Stainless steels Chlorinated oils or waxes Wiping roller
Polished surfaces Plastic film Calendaring, covering, spraying
Precoated materials Film/forced air

The effects of the process on the material's properties for this process are minimal. The physical
and chemical properties virtually have no change. But the process may cause workhardening,
microcracks, or thinning at bends when discussing the mechanical properties of the material.
The cost of roll forming is relatively low. Some things to be considered when calculating the cost
of the process are setup time, equipment and tool costs, load/unload time, direct labor rate,
overhead rate, and the amortization of equipment and tooling.
Safety is also a bit of an issue with this process. The main hazards that need to be taken into
consideration are dealing with moving workpieces (up to 800 feet per minute (240 m/min)), high
pressure rolls, or sharp, sheared metal edges.[1]

Advantages

Reduced labor and material handling

Faster, continuous production with reduced cost-per-piece

Greater accuracy, uniformity and consistency throughout both the individual piece and
production lots

The rollforming process can incorporate perforating, notching, punching, etc., thus reducing
secondary operations, parts rejections, and related costs

Precision parts facilitate savings in labor and costs

Speedier assembly resulting from part uniformity and tighter tolerances

Far longer lengths are achievable

More surface-friendly for prepainted, precoated and preplated metals

Two separate pieces/materials can be simultaneously formed, in a single operation, to
produce a strong composite part

High Velocity Hydroforming

Analogous to conventional hydroforming, in high rate hydroforming the force is applied via a solid, fluid
or gaseous working medium and thus, only one die is required, but in contrast to the quasistatic case,
Pascals principle is no longer valid here. Instead of a homogeneous pressure distribution in the fluid, here
a pressure impulse propagates through the fluid as a pressure wave or a shockwave (e.g. [Lan93]). This
pressure wave accelerates the workpiece in its propagation direction. According to the initiation
mechanisms of the shockwave

electrohydraulic forming,
explosive forming and propellant forming, and
the hydropunch process

can be distinguished.

Characteristics of a shockwave
A shockwave is characterized by

an expansion velocity that is (slightly) higher than the specific sonic speed of the working
medium,
an extremely fast pressure rise in the range of a few nanoseconds in low energy applications (e.g.
in an lithotripter) up to the range of a few microseconds in higher energy applications (i.e.
industrial applications as forming or destroying ceramic cores inside castings), and
a spatial form and expansion that depends on and can be influenced via the setup. Reflectors can
be used for directing or focusing the shockwave.

However, in an industrial application the forming process is the result of a pressure wave but not of the
shockwave. The expansion velocity of the shockwave is typically slightly higher than the specific sonic
speed of the working medium but the measured forming velocity is much lower. For example,
electrohydraulic forming tests with shockwave generation inside water result in an average forming
velocity of 67 m/s. The velocity maximum at the end of the forming process is between 250 and 300 m/s.
For comparison, the sonic speed in water is 1,450 m/s. On the other hand, it is possible to form metal
plates which are not in contact with the water surface, depending on the used pulse energy and the
electrode distance from the water surface. These perceptions explain that the electrohydraulic forming
process is a result firstly of the accelerated water in consequence of a water steam bubble generated by the
plasma channel and secondly of the inertia of masses of the workpiece.

The Hydroforming Process

Hydroforming was developed in the late 1940's and early 1950's to provide a cost effective means to
produce relatively small quantities of drawn parts or parts with asymmetrical or irregular contours that do
not lend themselves to stamping. Virtually all metals capable of cold forming can be hydroformed,
including aluminum, brass, carbon and stainless steel, copper, and high strength alloys.

A hydroforming press operates like the upper or female die element. This consists of a pressurized
forming chamber of oil, a rubber diaphragm and a wear pad. The lower or male die element, is replaced
by a punch and ring. The punch is attached to a hydraulic piston, and the blank holder, or ring, which
surrounds the punch.
The hydroforming process begins by placing a metal blank on the ring. The press is closed bringing the
chamber of oil down on top of the blank. The forming chamber is pressurized with oil while the punch is
raised through the ring and into the the forming chamber. Since the female portion of this forming method
is rubber, the blank is formed without the scratches associated with stamping.
The diaphragm supports the entire surface of the blank. It forms the blank around the rising punch, and
the blank takes on the shape of the punch. When the hydroforming cycle is complete, the pressure in the
forming chamber is released and the punch is retracted from the finished part.

Hydroforming Advantages

Inexpensive tooling costs and reduced set-up time.

Reduced development costs.
 Shock lines, draw marks, wrinkling, and tearing associated with matched die forming are
eliminated.
Material thinout is minimized.
Low Work-Hardening
Multiple conventional draw operations can be replaced by one cycle in a hydroforming press.
Ideal for complex shapes and irregular contours.
Materials and blank thickness specifications can be optimized to achieve cost savings.
Click here for more on Hydroforming

Manufacturing Costs: Hydroforming versus Deep Draw Stamping

Tooling - With low volume runs, tooling is often the most important cost consideration. With
hydroforming, a male die, or punch, and a blank holding ring are the only tools required as the rubber
diaphragm and pressurized forming chamber act as the female die. As a result, hydroforming tooling is
typically 50% less expensive than matched die tooling. With hydroforming, most punches are made from
cast iron as opposed to the hardened tool steels used for match die drawing punches. Finally,
hydroforming tools are easily mounted and aligned, making set-ups fast and efficient.

Development Costs - Proto-typing is often a necessary step in the manufacturing process. Changes in
material type or wall thickness specifications can typically be accommodated with hydroforming without
creating a need for new tooling.

Reduced Press Time - Complex parts requiring multiple press cycles in matched die operations can be
drawn in a single hydroforming cycle. Hydroforming presses frequently achieve reductions of 60-70%
compared to 35-45% for conventional matched die presses.

Finishing Costs - Aerospace, medical and commercial cookware applications often demand parts with
outstanding surface finishes. Unlike matched die metal forming, which can leave scratches and stretch
lines, the flexible diaphragm utilized in hydroforming eliminates surface blemishes, reducing the need for
costly finishing processes like buffing.

Electromagnetic Forming
Electromagnetic forming (EM forming or magneforming) is a type of high velocity, cold forming process
for electrically conductive metals, most commonly copper and aluminum. The work piece is reshaped by
high intensity pulsed magnetic fields that induce a current in the work piece and a corresponding
repulsive magnetic field, rapidly repelling portions of the work piece. The work piece can be reshaped
without any contact from a tool, although in some instances the piece may be pressed against a die or
former. The technique is sometimes called high velocity forming.

A rapidly changing magnetic field induces a circulating electrical current within a nearby conductor
through electromagnetic induction. The induced current creates a corresponding magnetic field around the
conductor. Because of Lenz's Law, the magnetic fields created within the conductor and work coil
strongly repel each other.
Fig. 1

When the switch is closed, electrical energy stored in the capacitor bank (left) is discharged through the
forming coil producing a rapidly changing magnetic field which induces a current to flow in the metallic
work piece (pink). The current flowing the work piece produces a corresponding opposite magnetic field
which rapidly repels the work piece from the forming coil, reshaping the work piece - in this case,
compressing the diameter of the cylindrical tube. The reciprocal forces acting against the forming coil are
resisted by the 'supportive coil casing.

In practice the metal work piece to be fabricated is placed in proximity to a heavily constructed coil of
wire (called the work coil). A huge pulse of current is forced through the work coil by rapidly discharging
a high voltage capacitor bank using an ignitron or a spark gap as a switch. This creates a rapidly
oscillating, ultrastrong electromagnetic field around the work coil.

The high work coil current (typically tens or hundreds of thousands of amperes) creates ultrastrong
magnetic forces that easily overcome the yield strength of the metal work piece, causing permanent
deformation. The metal forming process occurs extremely quickly (typically tens of microseconds) and,
because of the large forces, portions of the work piece undergo high acceleration reaching velocities of up
to 300 m/s.

Electromagnetic forming is the only high velocity forming technique to gain significant acceptance in
commercial metal working. The electromagnetic forming technique has been in use commercially for the
last 30 years. Mostly, it has been used for joining and assembly of concentric parts. The minimal
springback inherent in all high velocity forming processes provides high-quality joints.
Fig.2 Schematic illustration of electromagnetic forming showing a) solenoidal and b) flat forming coils.

One of the most common applications of electromagnetic forming is the compression crimp sealing and
assembly of axi-symmetric components such as automotive oil filter canisters. As the name implies, in
this technique, electromagnetic forces are used to form the material. A current pulse from a capacitor
bank is passed through a coil that is placed in close proximity to a work piece. The current pulse causes a
high-magnetic field around the coil. This field induces an eddy current in the work piece and an
associated secondary magnetic field. The two fields are repulsive and the force of magnetic repulsion
causes deformation of the work piece.

The designed shape and electrical characteristics of the coil depend on the work piece. Coils can be
developed for most practical forming geometries including forming of flat sheets. Fig. 2 is a schematic
illustration of electromagnetic forming showing a) solenoidal and b) flat forming coils.

The nature of the electromagnetic forming process makes it highly suitable for automation. Results
obtained are very repeatable because energy discharge characteristics are controlled essentially by the
non-changing electrical parameters of the system and precise control of capacitor bank charge voltage.
The fundamental physical characteristic of this technique is that the deformation forces initially are only
magnetic body forces generated within the material by eddy currents induced by the drive coils. Surface
pressures only occur upon contact with the form tool. This can provide deformation capabilities that are
difficult to obtain with other forming methods.

Although there are no fundamental limitations to the size of parts that can be made by electromagnetic
forming, larger parts require more energy, which translates into larger capacitor banks and higher initial
capital expenditure. As a result, hybrid forming processes are being considered, where electromagnetic
methods would be used only to form areas of the workpiece that can not be formed conventionally.
 In principle, both electromagnetic and electrohydraulic forming can be used in such a hybrid process. A
matched tool set with electromagnetic coils built into sharp corners and other difficult-to-form contours is
one way of forming these parts. Matched tools would be used to form sections of the work piece that can
be formed easily at low velocities using mechanical energy from the press.

This semi-formed work piece then would be subjected to high-velocity forming with electromagnetic
coils used to complete the forming operation. Similarly, a quasi-static, fluidpressure process, with an
electrical discharge in the fluid at the end of the pressure cycle to form sharp corners and bends, could
represent another hybrid method for making difficult parts, integrated into the tool assembly. However,
for many simpler parts, electromagnetic forming can be used right away, metals producers to automobile
and aerospace companies. Under the auspices of this consortium, a research program is being conducted
to understand the fundamentals of material behavior during high-rate forming while concurrently
developing practical forming technology. Even though more aspects of material behavior are beginning to
be understood and workable processes are being developed, further research is essential.

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. 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. Electromagnetic forming has a number of
advantages and disadvantages compared to conventional mechanical forming techniques.

Some of the advantages ie (over mechanical forming)

Improved formability (the amount of stretch available without tearing)

Wrinkling can be greatly suppressed

Forming can be combine with joining and assembling with dissimilar components including glass,
plastic, composites and other metals.

Close tolerances are possible as springback can be significantly reduced.

Single sided dies are sufficient which can reduce tooling costs

Lubricants are reduced or are unnecessary, so forming can be used in clean room conditions

Mechanical contact with the workpiece is not required, this avoids surface contamination and tooling
marks. As a result, a surface finish can be applied to the workpiece before forming.

The principle disadvantages are;

Non conductive materials cannot be formed directly, but can be formed using a conductive drive plate

The high voltages and currents involved require careful safety considerations
 Large sheet metal components cannot readily be formed, due to current limitations on the design of very
large coils

High Energy Rate Forming (HERF) Processes

Introduction:

The forming processes are affected by the rates of strain used.

Effects of strain rates during forming:

1. The flow stress increases with strain rates

2. The temperature of work is increases due to adiabatic heating.

3. Improved lubrication if lubricating film is maintained.

4. Many difficult to form materials like Titanium and Tungsten alloys, can be deformed

under high strain rates.

Principle / important features of HERF processes:

The energy of deformation is delivered at a much higher rate than in conventional

practice.

Larger energy is applied for a very short interval of time.

 High particle velocities are produced in contrast with conventional forming process.

The velocity of deformation is also very large and hence these are also called High

Velocity Forming (HVF) processes.

Many metals tend to deform more readily under extra fast application of force.

Large parts can be easily formed by this technique.

For many metals, the elongation to fracture increases with strain rate beyond the usual

metal working range, until a critical strain rate is achieved, where the ductility drops

sharply.

The strain rate dependence of strength increases with increasing temperature.

The yield stress and flow stress at lower plastic strains are more dependent on strain

rate than the tensile strength.

High rates of strain cause the yield point to appear in tests on low carbon steel that do

not show a yield point under ordinary rates of strain.

Advantages of HERF Processes

i) Production rates are higher, as parts are made at a rapid rate.

ii) Die costs are relatively lower.

iii) Tolerances can be easily maintained.

iv) Versatility of the process it is possible to form most metals including difficult to form

metals.

v) No or minimum spring back effect on the material after the process.

vi) Production cost is low as power hammer (or press) is eliminated in the process. Hence it

is economically justifiable.

vii) Complex shapes / profiles can be made much easily, as compared to conventional

forming.

viii) The required final shape/ dimensions are obtained in one stroke (or step), thus

eliminating intermediate forming steps and pre forming dies.

ix) Suitable for a range of production volume such as small numbers, batches or mass

production.
Limitations:

i) Highly skilled personnel are required from design to execution.

ii) Transient stresses of high magnitude are applied on the work.

iii) Not suitable to highly brittle materials

iv) Source of energy (chemical explosive or electrical) must be handled carefully.

v) Governmental regulations/ procedures / safety norms must be followed.

vi) Dies need to be much bigger to withstand high energy rates and shocks and to prevent

cracking.

vii) Controlling the application of energy is critical as it may crack the die or work.

viii) It is very essential to know the behavior or established performance of the work metal

initially.

Applications:

i) In ship building to form large plates / parts (up to 25 mm thick).

ii) Bending thick tubes/ pipes (up to 25 mm thick).

iii) Crimping of metal strips.

iv) Radar dishes

v) Elliptical domes used in space applications.

vi) Cladding of two large plates of dissimilar metals.

(I) Explosive Forming

Introduction:

A punch in conventional forming is replaced by an explosive charge.

Explosives used can be:

High energy chemicals like TNT, RDX, and Dynamite.

Gaseous mixtures

Propellants.

Factors to be considered while selecting an HERF process:

Size of work piece

Geometry of deformation
 Behavior of work material under high strain rates

Energy requirements/ source

Cost of tooling / die

Cycle time

Overall capital investment

Safety considerations.

Types of explosive forming:

1) Unconfined type or Stand off technique

2) Confined type or Contact technique

1) Unconfined Type (Or Stand Off Technique)

Principle:

The work is firmly supported on the die and the die cavity is evacuated. A definite

quantity of explosive is placed suitably in water medium at a definite stand off distance from the

work. On detonation of the explosive charge, a pressure pulse (or a shock wave) of very high

intensity is produced.

Fig. Unconfined Type Explosive Forming

A gas bubble is also produced which expands spherically and then collapses. When the

pressure pulse impinges against the work (plate or sheet0, the metal is deformed into the die

with a high velocity of around 120 m/s (430km/h).

The vacuum is necessary in the die to prevent adiabatic heating of the work which

may lead to oxidation or melting.

Role of water:

i) Acts as energy transfer medium

ii) Ensures uniform transmission of energy

iii) Muffles the sound of explosion

iv) Cushioning/ smooth application of energy on the work without direct contact.

Process Variables

i) Type and amount of explosive: wide range of explosive sis available.

ii) Stand off distance SOD- (Distance between work piece and explosive): Optimum SOD

must be maintained.

iii) The medium used to transmit energy: water is most widely used.

iv) Work size:

v) Work material properties

vi) Vacuum in the die

Advantages;

i) Shock wave is efficiently transmitted through water and energy is transmitted effectively

on the work

ii) Less noise

iii) Less probability of damage to work.

iv) Large and thick parts can be easily formed

v) Economical, when compared to a hydraulic press

Limitations:

i) Optimum SOD is essential for proper forming operation.

ii) Vacuum is essential and hence it adds to the cost.

iii) Dies must be larger and thicker to withstand shocks.

iv) Not suitable for small and thin works.

v) Explosives must be carefully handled according to the regulations of the government.

Applications:

Ship building,

Radar dish,

Elliptical domes in space applications

2) Confined System ( OrContact Technique)

Principle:

The pressure pulse or shock wave produced is in direct contact with the work piece

(usually tubular) and hence the energy is directly applied on the work without any water

medium.

The tube collapses into the die cavity and is formed. It is used for bulging and flaring

operations.

Fig. Confined (Contact) type Explosive Forming

Advantages:

i) Entire shock wave front is utilized as there is no loss in water.

ii) More efficient as compared to unconfined type.

Disadvantages:

i) More hazard of die failure

ii) Vacuum is required in the die

iii) Air present in the work piece (tube) is compressed leading to heating.

iv) Not suitable for large and thick plates.

Applications;

Bulging and flaring of tubes.

 Spinning:
Metal spinning, also called conventional spinning or just spinning, is the forming of an axis-
symmetric part over a rotating mandrel. Force is delivered by a tool with a rounded end or a
roller. A flat, or possibly preformed, work piece is held between a mandrel and tail stock. As the
apparatus rotates, the tool applies localized pressure to the work while it gradually moves up the
mandrel. This causes the sheet metal work to be wrapped over the mandrel, thus taking its shape.
Metal spinning is commonly performed cold, but in some cases parts may be subject to warm or
hot spinning. Spinning is capable of producing large parts with diameters as high as 20 feet.

The tooling in a metal spinning operation is generally made from tool steel. The mandrel in some
cases may be made of wood. Containers with bottle or tapered necks can be manufactured on
collapsible mandrels, that are disassembled and removed from the formed parts. Set up costs for
metal spinning are usually low. Conducting a spinning operation is relatively expensive on a per
unit basis. Deep drawing is usually the main alternative manufacturing method to metal spinning,
for producing parts. In contrast, deep drawing often requires a high initial investment for set up,
while the cost of production per part is low. For these reasons, deep drawing is more useful for
mass production of parts. Spinning is employed for small numbers of parts, unique, curved, or
varied parts and large parts. Operator skill is important in metal spinning. CNC machinery is
now replacing the operator in many cases. CNC spinning gives a high quality consistent product.

Tools used in spinning

The basic hand metal spinning tool is called a spoon, though many other tools (be they
commercially produced, ad hoc, or improvised) can be used to effect varied results. Spinning
tools can be made of hardened steel for using with aluminium or solid brass for spinning
stainless steel or mild steel.

Some metal spinning tools are allowed to spin on bearings during the forming process. This
reduces friction and heating of the tool, extending tool life and improving surface finish.
Rotating tools may also be coated with thin film of ceramic to prolong tool life. Rotating tools
are commonly used during CNC metal spinning operations.

Commercially, rollers mounted on the end of levers are generally used to form the material down
to the mandrel in both hand spinning and CNC metal spinning. Rollers vary in diameter and
thickness depending the intended use. The wider the roller the smoother the surface of the
spinning; the thinner rollers can be used to form smaller radii.

Cutting of the metal is done by hand held cutters, often foot long hollow bars with tool steel
shaped/sharpened files attached. In CNC applications, carbide or tool steel cut-off tools are used.

The mandrel does not incur excessive forces, as found in other metalworking processes, so it can
be made from wood, plastic, or ice. For hard materials or high volume use, the mandrel is usually
made of metal.

Advantages & disadvantages

Several operations can be performed in one set-up. Work pieces may have re-entrant profiles and
the profile in relation to the center line virtually unrestricted.

Forming parameters and part geometry can be altered quickly, at less cost than other metal
forming techniques. Tooling and production costs are also comparatively low. Spin forming,
often done by hand, is easily automated and an effective production method for prototypes as
well as high quantity production runs.

Other methods of forming round metal parts

include hydroforming, stamping, forging and casting. These other methods generally have a
higher fixed cost, but a lower variable cost than metal spinning. As machinery for commercial
applications has improved, parts are being spun with thicker materials in excess of 1in (25mm)
thick steel. Conventional spinning also wastes a considerably smaller amount of material than
other methods.

Objects can be built using one piece of material to produce parts without seams. Without seams,
a part can withstand higher internal or external pressure exerted on it. For example: scuba tanks
and CO2 cartridges.

One disadvantage of metal spinning is that if a crack forms or the object is dented, it must be
scrapped. Repairing the object is not cost-effective.
 Shear Spinning

Shear spinning is a process related to conventional spinning and is also known as flow turning or
spin forging. In a conventional spinning operation the work is essentially formed by bending.
There is usually not much change in the thickness of the sheet metal. The diameter of the work in
conventional spinning must be large enough to account for the size of the final part. Shear
spinning involves forming the work over the mandrel, causing metal flow within the work. This
metal flow will act to reduce the thickness of the work as it is formed. The initial diameter of the
work can be smaller in shear spinning. Limits to the amount of reduction of work thickness exist
in order to prevent fracture. Coolants are normally used in shear spinning, since this
manufacturing process can generate a lot of heat. One or two rollers, (tools), may be used, two
will provide a better balance of forces during the operation. Shear spinning of some materials
will be conducted at elevated temperatures.shear spinning, is similar to metal spinning. In shear
spinning the area of the final piece is approximately equal to that of the flat sheet metal blank.
The wall thickness is maintained by controlling the gap between the roller and the mandrel.
In shear forming a reduction of the wall thickness occurs.
Before the 1950s, spinning was performed on a simple turning lathe. When new technologies
were introduced to the field of metal spinning and powered dedicated spinning machines were
available, shear forming started its development in Sweden.

Workpiece and roller tool profiles

In shear forming, the starting workpiece can have circular or rectangular cross sections. On the
other hand, the profile shape of the final component can be concave, convex or a combination of
these two.
A shear forming machine will look very much like a conventional spinning machine, except for
that it has to be much more robust to withstand the higher forces necessary to perform the
shearing operation.

The design of the roller must be considered carefully, because it affects the shape of the
component, the wall thickness, and dimensional accuracy. The smaller the tool nose radius, the
higher the stresses and poorest thickness uniformity achieved.

Spinnability
Spinnability, sometimes referred as shear spinnability, can be defined as the ability of a metal to
undergo shear spinning deformation without exceeding its tensile strengthand tearing. Published
work on spinnability is available from the authors Kegg and Kalpakcioglu.

Kegg predicted that for materials with a tensile reduction of 80%, the limiting spinning reduction
will be equal or greater than 80%. Kalpakciouglu concluded that for metals with a true fracture
strain of 0.5 or greater, there is a maximum limit for the shear forming reduction. For materials
with a true strain below 0.5, the spinnability depends on the ductility of the material.

Highly spinnable materials include ductile materials like aluminum and certain steel alloys.

Tube Spinning
Tube spinning is performed on cylindrical parts. Tube spinning is similar to shear spinning in
that metal flow occurs within the work. This metal flow acts to reduce the thickness of the metal.
While using tube spinning to reduce the thickness of the tube, the tube's length will be increased.
This manufacturing process can be performed externally with the tube over a mandrel or
internally with the tube enclosed by a die. The tool can also in some cases be moved during the
operation, in order to create contours or features on the inside or outside of the tube.
 Flow forming
Flow Forming is an incremental metal forming technique in which a disk or tube of metal is
formed over a mandrel by one or more rollers using tremendous pressure. The roller deforms the
workpiece, forcing it against the mandrel, both axially lengthening and radially thinning
it.[1] Since the pressure exerted by the roller is highly localized and the material is incrementally
formed, often there is a net savings in energy in forming over drawing or ironing processes.
However, these savings are often not realized because of the inherent difficulties in predicting
the resulting deformation for a given roller path. Flow forming subjects the workpiece to a great
deal of friction and deformation. These two factors may heat the workpiece to several hundred
degrees if proper cooling fluid is not utilized.

Flow forming is often used to manufacture automobile wheels and can be used to draw a wheel
to net width from a machined blank.

During flow forming, the workpiece is cold worked, changing its mechanical properties, so its
strength becomes similar to that of forged metal.
Features
The unique features of the flowforming process allow for innovative, cost-effective engineering
or redesign of your product or part, resulting in the following features:

Traditional multi-piece designs can be formed as a single, seamless piece

Increase mechanical properties, such as tensile/yield strength and hardness

Provide design versatility to produce a unique seamless profile with varying wall thicknesses

Produce cylindrical, conical, or contoured shapes up to 47" diameter

Typical interior finishes of 15Ra without additional manufacturing steps

High material utilization from near-net shape forming process

What Makes a Component Ideal for Flow Forming?

Symmetry around a centreline - cones and cylinders (or a combination).

Final part wall thicknesses between .020 and .200in.

Diameters between 1 and 24in.

Length-to-diameter ratios greater than 2.5 to 1.

Controlled variations in wall thickness, especially where there are heavy bottoms and thinner
side walls.

Difficult-to-form materials, including stainless steel, Hastelloy, Inconel, and other heat-resisting
alloys.

Requirements for various additional manufacturing processes, including machining, welding, or

finishing.

Parts that can benefit from the effects of coldworking on the material- increased strength and
wear resistance, harder surfaces.

Tolerances that exceed the capabilities of deep drawing or spinning requiring precision that
approaches machined parts.

Parts that can benefit from design changes to optimise the effectiveness of flowforming - without
adversely affecting function.

Parts capable of carrying a higher overhead than is incurred with simple stamping, sheet-metal
bending, or other basic forming operations.