Chip-free spinning and in-process trimming for robotic automation

Controlled spinning with integrated trimming and real-time chip extraction.

Clean process environment enabling stable robotic integration and fully automated production.

The Challenge

An aluminium components manufacturer aimed to fully automate its production line, integrating a robot to handle parts immediately after the spinning process.

The components were produced on a DENN NTR-100/30 CNC metal spinning machine, used for manufacturing aluminium downpipes.

However, the process required cutting the part during the spinning operation, which created a major obstacle for automation.

Simultaneous trimming generated aluminium chips and fragments that dispersed inside the machine.

This accumulation caused several critical issues:

• Jamming of the cutting tool
• Chips adhering to the spinning roller, affecting process stability
• Dirty and unstable working environment
• Inability to reliably integrate robotic handling

Although the spinning process itself performed correctly, the presence of chips made full automation of the production line unfeasible.

The challenge was therefore to maintain trimming during spinning while ensuring a clean and controlled production environment compatible with robotic operation.

The DENN Solution

DENN approached the situation as a complete process engineering challenge, rather than as a simple mechanical limitation.

The objectives were clear:

• Allow trimming during the spinning operation
• Control and remove chips in real time
• Maintain a clean and stable environment for safe robot operation

Achieving this required a redesign of the interaction between machine structure, cutting system and automation integration.

Three key actions were implemented.

First, the machine bed was specifically modified to accommodate the new trimming and extraction system without interfering with the spinning process or the robot access area.

Second, a high-performance industrial suction system was installed and focused directly on the trimming zone. This system captures aluminium chips at the moment they are generated, preventing them from dispersing inside the machine.

Third, the cutting tool was fully automated and synchronised with the spinning process.
The tool follows the rotating disc with precise positioning, performing the trimming operation exactly where required while all chips are simultaneously extracted and directed into a dedicated collection tank.

The Result

The redesigned process environment enabled the complete automation of the production line.

The solution delivered:

• Chip-free machine interior after trimming operations
• Continuous and stable spinning cycles
• Reliable robotic part handling without interference
• Clean and controlled working environment
• Reduced process interruptions and maintenance needs
• Improved overall production productivity

Once the spinning and trimming operations are completed, the robot can enter the machine area and manipulate the part without any obstruction, allowing seamless integration into the automated production line.

Why It Matters

Successful automation in metal forming depends not only on machines or robots, but on complete process integration.

By combining machine design, cutting technology, chip management and automation strategy, DENN transformed a conventional spinning process into a clean, stable and fully automated production solution.

At DENN, we do not simply build machines.

We engineer complete forming processes that perform reliably in real industrial environments.