In the metalworking industry, research and development (R&D) is vital for a successful manufacturing project.
After the initial product design, prototyping is the ideal next step in process; though producing a one-off part or component may seem like a simple task, this step is not without its issues. Prototyping can often consume time, leading to production delays, and tooling can cut into your company’s budget.
At Helander, we have provided clients with custom forming and fabrication services for the last 80 years. Our extensive experience has enabled us to specialize in several areas, but one of our core competencies is metal spinning.
Metal spinning is an ideal process for manufacturing high-quality round parts of different sizes and shapes—such as hemispheres and spheres. Our spherical metal parts are created simply and easily by joining two spun hemispheres; the resulting hollow spheres are imbued with the resiliency needed for the most demanding commercial and industrial applications.
When considering the numerous options available for working with metal, many companies choose the beneficial and cost effective process hydroforming. Originally developed around 1950, hydroforming is ideal for shaping many types of ductile metals, including brass, aluminum, stainless and low alloy steels. It holds a number of benefits when compared to similar work processes, especially when considering cost, precision, and efficient operation. One area where hydroforming especially excels is its role in minimizing secondary finishing operations.
The American Society of Mechanical Engineers (ASME) first published the Boiler & Pressure Code (BPVC) in 1915 in response to the need for safety measures in the production and use of boilers and pressure vessels. In the early 1900s, boilers and pressure vessels – closed containers designed to hold gases or liquids at a pressure substantially different from the ambient pressure – were new innovations. These innovations promoted and advanced industrial activity in the U.S., specifically for companies that utilized machines for long-range transportation and heavy lifting.
Metal Spinning has a long history that spans back to ancient Egypt and has progressed through the years to today’s more advanced methods of forming metal via spinning it. Today, the modern metal spinning process takes place on rigid lathes that incorporate high velocity spindles that shape the metal. These spindles are operated either manually or via advanced computer controls.
Metal Spinning is a process by which a disc or tube of ductile metal is rotated on a spindle and formed into an axially symmetric part. Through the use of heavy forces and high speeds, the metal will deform and “flow” to form the desired shape around a mandrel, a kind of mold that is shaped to the interior geometry of the planned part. This process allows metal to deform evenly, without any wrinkling or warping, to create a smooth, even, and seamless surface. The processes’ heavy forces also realign and strengthen the grain structure, significantly increasing the tensile properties and fatigue resistance of the base material.
Metal forming and fabricating are our business here at Helander, so we’re lucky to be so close to the annual Fabtech conference held just up the road in Chicago, this year at McCormick Place. This year’s show, held from November 12th through November 14th, proved just as educational, interesting, and, most of all, fun as in years past. Walking around, taking in all the different booths and displays, it’s quickly apparent that a good 50% or more of the exhibits focus on metalforming – certainly of interest to us, but not quite up our alley, not quite the art of metal spinning.
