Spinning Machine & Flow Forming Machine | Nihon Spindle Manufacturing Co., Ltd.

Features of flow forming (metal spinning)

The flow forming is a transforming process that a metal plate or cup-shaped metal workpiece is rotated over a mandrel while a roller deforms the workpiece, forcing it against the mandrel. The process allows you to stretch the material thinly, thicken it, or cleave and expand it as if working with dough. As a result, you can form metal into shapes that are not conceivable with traditional processing work. This process can be used to fabricate workpieces of a variety of shapes without leaving cutting flakes, offering greater freedom of component design. It can be roughly divided into the following process methods.

Machines
Process Methods
Examples of applications

>　Aluminum Wheel Forming Machines
>　Spinning Machines for Exhaust products
>　Flow Forming Machines for Transmission parts
>　Thickening, Cleaving and Rolling Machines
>　General-Purpose Machines
>　Specialized machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Flow Forming
Spinning
Cleaving
Thickening
Gear-Rolling

Flow Forming: Force the material against a die so that it imprints the shape of the die.

Flow Forming benefit [1]: Pressing the material between a die and a roller can increase the density of the material’s tissues, substantially enhancing its strength. This process can reduce the thickness or eliminate the subsequent heat-treatment process.

Flow Forming benefit [2]: Tube necking, or partial reduction of tube thickuess makes it possible to thicken specified part where higher strength is required, which has been unachievable with any traditional method.

Available machine types

>　Aluminum Wheel Forming Machines
>　Flow Forming Machines for Transmission parts
>　Thickening, Cleaving and Rolling Machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Spinning: Necking a tube, or partially reducing the thickness. A tube can be formed even with parts installed inside.

Spinning benefits: Even difficult-to-process materials as well as complex shapes that would require multiple dies in pressing process can usually be handled using only a single die. Curling and trimming can also be processed by changing tools during spinning.

Available machine types

>　Spinning Machines for Exhaust products
>　General-Purpose Machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Cleaving: Split the material into a Y- or T-shaped section. This method allows part integration, eliminating the need for welding.

Example of benefits of Flow Forming and Cleaving: Spline forming, which is usually made through machining, and hub forming, which is usually achieved by welding separate parts, can be simply done by welding-free, machining-free flow forming.

Available machine types

>　Aluminum Wheel Forming Machines
>　Flow Forming Machines for Transmission parts
>　Thickening, Cleaving and Rolling Machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Thickening: Thicken the material to produce a partially thickened piece.

Example of benefits from thickening and gear rolling process: It is possible to integrate a disk plate, such as “Drive plate” and ring gear part in one solid part without welding process. Also it is possible to process O-ring groove and roll gear by imprinting the roller shape on the part.

Available machine types

>　Aluminum Wheel Forming Machines
>　Flow Forming Machines for Transmission parts
>　Thickening, Cleaving and Rolling Machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Gear-Rolling: Transfer the contour of a roller to the material, making O-ring grooves or splines.

Example of benefits from thickening and gear rolling process: It is possible to integrate a disk plate, such as “Drive plate” and ring gear part in one solid part without welding process. Also it is possible to process O-ring groove and roll gear by imprinting the roller shape on the part.

Available machine types

>　Aluminum Wheel Forming Machines
>　Flow Forming Machines for Transmission parts
>　Thickening, Cleaving and Rolling Machines

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.

Automotive parts

1Poly V pulley: Available machine typesThickening, Cleaving and Rolling Machines

2Drive plate: Available machine typesThickening, Cleaving and Rolling Machines

3AT clutch: Available machine typesFlow Forming Machines for Transmission parts

4Brake piston: Available machine typesThickening, Cleaving and Rolling Machines

5Catalytic converter and muffler: Available machine typesSpinning Machines for Exhaust products

6Differential gear: Available machine typesFlow Forming Machines for Transmission parts

7Aluminum wheel: Available machine typesAluminum Wheel Forming Machines

CVT Pulley(motorcycle): Available machine typesFlow Forming Machines for Transmission parts

Applications other than automotive parts

Thermos inner bottle: Available machine typesThin Wall Tube Forming Machine

Gas Cylinder: Available machine typesGas Cylinder Necking

Printer roller: Available machine typesThin Wall Tube Forming Machine

Features of Nihon Spindle Flow Forming (Spinning) machines

Best cost performance with optimal design: Machine specifications can be determined based on thrust measurement data obtained during the actual trials with R&D machine. Along with structural analysis, it is possible to offer “JUST-FIT” machine.

Aggressive use of a servo motor driving method for lower running cost: All roller units are driven by electric servo motors, which can reduce running cost by 30% to 50% against a conventional hydraulic servo method (compared to our company products). Reduction of hydraulic driving units leads to lower noise and less oil leakage.

Independent roller control for various processes: Each flow forming roller has their own control axis, which can be used to reduce cycle time by overlapping rollers. It is also easy to set each roller position for each axes by NC program.

Adopt “Processing chamber” concept: Processing chamber is completely isolated from the control unit and driving unit to avoid malfunction and other mechanical issues due to intrusion of coolant or sludge. This concept also offers easy cleaning of the machine.

Optional mandrel exchange unit for smoother change-over: Mandrel exchange unit and roller exchange unit are optionally available for smoother change-over due to a blocked top section of the machine.