Vertical CNC Split Spinning Machine

Vertical CNC Split Spinning Machine

The BXPKX50-III Vertical CNC Split Spinning Machine is developed for the precision forming of V-groove pulleys, lightweight wheels and other rotationally symmetrical metal components. It combines edge splitting, groove preforming and profile finishing in a CNC-controlled production system.

A carbide-tipped splitting wheel first separates and redistributes the edge material of the rotating blank. Additional forming rollers then progressively shape the divided material into the required V-groove or rim profile.

With three-station tooling, automatic loading and unloading, high-pressure water cooling and stepless spindle speed control, the machine is suitable for repetitive production of aluminum alloy and mild steel components.

Split spinning is a rotary metal-forming process used to divide and shape the edge of a circular blank.

During processing, the blank rotates at a controlled speed while a pointed splitting roller moves into its outer edge. The roller separates the material into two sections without cutting away the entire edge. Forming rollers then expand, compress or reshape the separated sections into the required profile.

The process is commonly used to produce integral V-groove pulleys and lightweight wheels from a single metal blank.

Compared with assembling a pulley from several separately manufactured parts, integral split spinning can reduce joining procedures and create a continuous formed structure.

Split Spinning Process

A typical production cycle includes the following steps:

1. The blank is transferred to the loading position.

2. The automatic loading system places the blank in the fixture.

3. The workpiece is securely clamped on the vertical spindle.

4. The spindle accelerates to the programmed forming speed.

5. The carbide-tipped roller pre-splits the blank edge.

6. Additional rollers progressively form the required groove profile.

7. The final tooling station calibrates the dimensions and surface profile.

8. High-pressure water cooling controls heat and lubricates the forming area.

9. The spindle stops and the finished component is automatically unloaded.

The exact roller sequence and number of passes are determined by the workpiece material, thickness and final geometry.

Typical Products

The BXPKX50-III can be evaluated for manufacturing:

• Single V-groove pulleys

• Multi-groove V-belt pulleys

• Automotive belt pulleys

• Agricultural machinery pulleys

• Tractor pulley components

• Washing machine pulleys

• Fan and motor pulleys

• Lightweight metal wheels

• Circular transmission components

• Split-rim metal parts

• Customized rotational components

The machine is particularly suitable for components that require a consistent circular profile and repeatable groove dimensions in batch production.

Typical Industries

Automotive Components

Split spinning can be applied to belt pulleys, drive-system components and lightweight circular parts used in automotive assemblies.

Agricultural Machinery

The process is suitable for pulley components used in tractors, harvesters, pumps and other agricultural equipment.

Home Appliances

Washing machines, dryers and other appliances may use formed pulleys that require controlled groove geometry and stable batch consistency.

Motors and Industrial Fans

The machine can produce selected pulley and wheel components used in motor-driven and fan-driven transmission systems.

General Machinery

Customized rotating parts can be developed for conveyors, pumps, compressors and industrial power-transmission equipment.

Main Advantages

Single-Clamping Forming

Splitting, groove forming and profile calibration can be completed while the workpiece remains in one clamping position.

Reducing repeated removal and repositioning helps control cumulative positioning deviations between different forming stages.

Carbide-Tipped Splitting Wheel

The pointed carbide splitting wheel is designed for the initial separation and preforming of the blank edge. Its hardness supports repeated contact with the workpiece during production.

The splitting wheel geometry should be selected according to the material thickness, groove position and required material flow.

Three-Station Tooling

The machine has three tooling stations that can accommodate different rollers for sequential processing.

A typical arrangement may include:

• First station: edge splitting

• Second station: groove expansion or preforming

• Third station: profile finishing and calibration

The actual arrangement can be customized according to the pulley or wheel design.

Automatic Loading and Unloading

Automatic material handling reduces repeated manual loading operations and supports consistent production cycles.

It can also simplify integration with upstream blank-feeding equipment and downstream inspection or collection systems.

High-Pressure Water Cooling

High-pressure water cooling provides lubrication and helps manage heat generated between the spinning rollers and workpiece.

Appropriate cooling can support stable continuous operation and reduce excessive heat accumulation around the tooling area.

Stepless Spindle Speed Control

The spindle speed can be adjusted within the listed range of 0–500 rpm. Different speeds can be programmed for splitting, groove forming and finishing stages.

This allows the forming process to be adjusted according to blank diameter, material characteristics and required surface quality.

Vertical Machine Configuration

The vertical arrangement allows the circular blank to be positioned around the spindle axis and can simplify automatic loading for selected pulley and wheel components.

It also provides a compact production layout for circular workpieces within the machine’s processing range.

Processable Materials

The machine is primarily designed for ductile metals suitable for rotary splitting and forming, including:

• Aluminum alloys

• Mild steel

• DC01 cold-rolled steel

• DC02 cold-rolled steel

• DC03 cold-rolled steel

• DC04 cold-rolled steel

• DC05 cold-rolled steel

• DC06 cold-rolled steel

The suitability of a material should be evaluated according to its tensile strength, yield strength, elongation, hardness and work-hardening behavior.

Materials with lower ductility may require:

• A larger splitting radius

• Reduced deformation in each pass

• Additional forming stages

• Different roller geometry

• Process lubrication adjustments

• Intermediate heat treatment in special cases

Customers should provide the complete material designation instead of only stating “steel” or “aluminum.”

Why Use Split Spinning for V-Groove Pulleys?

V-groove pulley production requires control over groove angle, width, depth, concentricity and circular runout.

The split spinning process forms the groove from the material already present around the edge of the blank. This makes it possible to create an integral pulley profile without assembling multiple stamped or machined sections.

Potential production benefits include:

• Fewer separate component-forming steps

• Reduced joining and welding requirements

• Lower material removal than full machining

• Flexible groove-profile development

• Repeatable CNC roller paths

• Suitability for automated batch production

• Ability to form lightweight pulley structures

The actual economic advantage depends on the product design, annual quantity, tooling cost and required finishing operations.

Key Quality Requirements for Finished Pulleys

When evaluating a split-spun pulley, manufacturers should inspect more than the outside diameter.

Important quality items include:

• Groove angle

• Groove width and depth

• Groove spacing

• Wall-thickness distribution

• Pulley concentricity

• Circular runout

• Axial runout

• Surface condition

• Edge cracking

• Material folding

• Final product weight

• Fit with the belt specification

Inspection requirements and tolerances should be defined before tooling and machine programs are developed.

How to Select a Split Spinning Machine

Machine selection should be based on the finished component and production process rather than the product name alone.

Provide the following information for technical evaluation:

1. Finished product drawing

2. Initial blank drawing

3. Blank outer and inner diameters

4. Initial material thickness

5. Material grade and mechanical properties

6. Number of V-grooves

7. Groove angle, width and depth

8. Final pulley diameter

9. Dimensional and runout tolerances

10. Required surface condition

11. Expected cycle time

12. Monthly or annual production quantity

13. Upstream feeding method

14. Downstream inspection requirements

Boxiang can use this information to assess the spindle, clamping fixture, splitting wheel, forming rollers and CNC process.

BXPKX50-III vs. BXPKX500-III

The BXPKX50-III should be considered for components within its confirmed blank and thickness range. The BXPKX500-III provides greater listed diameter and thickness capacity for larger pulleys and heavier workpieces.

Final model selection must be confirmed using the customer’s product drawing and material specifications.

Customized Tooling and Process Development

Every V-groove pulley has different requirements for material flow, groove geometry and final tolerances. The machine therefore needs to be matched with workpiece-specific tooling and programs.

Customization can include:

• Blank positioning fixtures

• Workpiece clamping systems

• Carbide splitting wheels

• Groove preforming rollers

• Final calibration rollers

• Multi-groove tooling

• CNC roller-path development

• Automatic blank-feeding systems

• Finished-part unloading devices

• Cooling and filtration systems

• Safety guarding

• In-line inspection integration

Sample forming is recommended for new pulley structures or materials that have not previously been processed by split spinning.