electro magnetic forming- metal spinning-peen forming

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4.2- Electro magnetic forming-
Metal spinning-Peen forming

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9. • The energy stored in a capacitor bank is discharged
rapidly through a magnetic coil.
• EX: a ring shaped coil is placed over a tubular workpiece.
• Depends upon the shape of the die the tube will deform
when the magnetic force pushes the metal.
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10. • The magnetic field produced by the coil crosses the metal
tube(conductor) and so generates eddy currents in the tube.
• These current in turn, produces their own magnetic field.
(see fig)
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A localized electric current induced
in a conductor by a varying

11. • The forces produced by the two magnetic fields oppose
each other, consequently there is a repelling force between
the coil and the tube.
• The forces generated collapse the tube over the inner piece.
• The higher the electrical conductivity of the workpiece, the
higher the magnetic forces.
• It is not necessary for the workpiece material to have magnetic
properties. (We can use some conducting layer strip)
• Flat magnetic coils are also available, for the operations of
embossing and of shallow drawing on sheet metals.
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13. • Magnetic-pulse forming is used for collapsing thin walled tubes
over rods, cables and plugs, for compression- crimp sealing
of automotive oil filter canisters, for bulging and flaring
operations and for swaging end fittings on to torque tubes
for the Boeing 777 aircraft.
• Producing bulging of tube, shrinkage of tube
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14. • Advantages
• Used to form uniform rate of forming
• Good surface finish products
• Time of operation is less as compared to conventional process
• Disadvantages:
• Non-conducting materials are not processed without aid of
conducting materials
• It is limited for sheet metal forming process not an forming buld
material.
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16. • Metal spinning, also known as spin forming or
spinning or metal turning most commonly, is a
metalworking 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
Manual or by a CNC lathe(power
spinning)
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17. • Process:
• A circular block is centered on a lathe which is placed
against a form block.
• The form block is mounted on the head stock of the spinning
lathe.
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Commercial applications include rocket nose
cones, cookware, gas cylinders, brass
instrument bells, and public waste receptacles
Form
block

18. • The blank is tightly held between form block and tail
stock spindle.
• The required contour surface is made on the form
block.
• The pressure is applied by the roller type forming
tool which is placed on the tool post of the spinning
lathe.
• Spinning roller is attached with a T-rest lever bars.
• The required shape is gradually formed by
continuous application of pressure by the roller.
• During spinning process, some stretching and
thinning of material take place.YoucaN

19. • It may suitable for both hot and cold
working.
• Aluminium copper, brass and stainless steel
can also be spun in spinning process.
• This process is mainly suitable for producing
conical shape parts and suitable for low
volume production.
• Components produced in this process do
not require any trimming or beading
operations.
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20. • Advantage:
• Objects not be drawn by drawing operations
can be easily formed in spinning
• Economical for low volume production
• Disadvantages
• Thinning takes place during spinning process
• More complex shapes required segmental
chucks.
• Accuracy and quality of finished productsYoucaN

21. • Accuracy of spinning is less in manual spinning
process.
• Even though segmental chucks used some complex
shapes can not be formed.
• Also to reduce machining time, spinning machines
are referred as power spinning.
• Nuclear controls method is used to control the form
tool.
• Most of the power spinning process is done in HMTYoucaN

22. • Spinning of sheet metal is done automatically but the
loading and unloading of sheet metal are done
manually.
• The contour shape can be obtained with one pass of
roller or multiple pass.
• Advantage- less time, more thickness can be easily
handled, accurate one, high volume production.
• Application- flower pots, lamp shades, missile and
radar units, jet plane componentsYoucaN

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26. • Peen forming is a process of well established surface
cleaning.
• In this process, a stream of metal shots is blasted
against the surface of the blank to be made in to
required shape.
• Used to produce curvatures on thin sheet metals by
shot peening one surface of the sheet.
• Surface of the sheet is subjected to compressive
stresses. The local plastic deformation in metal
improves the fatigue strength.
• The process also induces compressive residual
stresses (the stress present in an object in the
absence of any external load or force), which improve
the fatigue (structural damage from repeated loading)YoucaN

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Surface contains tension will fail first. So our idea is creating
compression on both the sides

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30. • Surface spreads plastically, due to that the crack
propagation in a material is eliminated. (crack initiation is
avoided so fatigue strength increases a lot)
• Shot peening increase fatigue life up to 1000%.
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36. • Advantages:
• Complex contours can be produced easily
• Peening is also used as salvage operations for correcting
bent
• Does not required any punch and die.
• Disadvantage:
• Requires longer time for forming the required shape,
requires additional devices for forcing out metal shots.
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