Category Archives: Industrial Supply

What is Aluminum Extrusion and The Benefits of Custom Aluminum Extrusion Fabrication

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Aluminum extrusion is a process that shapes aluminum by forcing it through a die. It produces complex and lightweight parts that are strong and uniform. The parts are treated to improve their properties and can be customized to fit specific needs. Custom aluminum extrusion fabrication is a fast and cost-effective way to create high-quality components for various industries. It has many benefits, such as corrosion resistance, thermal and electrical conductivity, and aesthetic appeal. Custom aluminum extrusion fabrication is a key technology for modern manufacturing.

What is Aluminum Extrusion

Types of custom aluminum extrusions
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Aluminum extrusion is an industrial process that shapes aluminum by forcing it through a die with a specific cross-sectional profile. This method allows for the production of complex and lightweight components that are structurally strong and consistent in shape. The extrusion process begins with the selection of the appropriate aluminum alloy, such as 6061 or 7075, which is then heated and pushed through the die. The extruded material is cooled, hardened, and subjected to various treatments like T5 or T6 to achieve the desired mechanical properties. This process is ideal for creating a wide range of products, from simple angles and channels to intricate custom profiles.

Customization and Precision in Aluminum Extrusion Fabrication

Custom aluminum extrusion fabrication stands out for its ability to produce tailor-made solutions for specific industry needs. By designing a unique die, manufacturers can create profiles that perfectly match the requirements of their applications. The advanced technology involved in the extrusion process, including 3-axis and 5-axis milling machines, ensures high precision and quality. The material’s thickness, dimensions, and component weight can be controlled with tight tolerances, resulting in parts that meet the most demanding specifications. This level of customization and precision is invaluable for industries ranging from automotive to construction, where specialized components are essential.

The Benefits of Custom Aluminum Extrusion Fabrication

The benefits of custom aluminum extrusion fabrication are numerous and impactful. This process allows for on-demand delivery of extrusion parts, facilitating cost-effective series production. The use of aluminum in extrusion offers a lightweight yet durable solution, with the added advantage of being corrosion-resistant. Custom extrusions can also be designed to optimize thermal and electrical conductivity, making them suitable for applications such as electrical systems and cooling devices. Furthermore, surface treatments like anodizing and powder coating enhance the appearance and longevity of the components. With its combination of efficiency, versatility, and quality, custom aluminum extrusion fabrication is a cornerstone in modern manufacturing.

Precision Aluminum Extrusion by DMS Group

DMS Group is a leading provider of aluminum extrusion services, offering customization options using different aluminum alloys like 6061 and 7075. They can handle a wide range of material thicknesses and component weights, catering to both complex and large-scale extrusion needs.

DMS utilizes cutting-edge extrusion methods to ensure high accuracy and quality in the production process. They also provide various surface treatments like anodizing and powder coating to enhance the performance and appearance of components.

DMS Group is dedicated to delivering extrusions that meet the highest quality standards and adhere to your delivery schedule. Their service is tailored to your exact specifications, from design to the final product. They employ the latest extrusion technology and work with different aluminum series to create lightweight and durable parts.

With a commitment to precision, DMS Group guarantees tolerances up to 0.1 mm. They also offer heat treatment options like T4, T5, and T6 to optimize material properties for specific applications. Their goal is to provide flawlessly crafted solutions that are delivered on time to support your project.

Visit and find out more : https://www.dmsgroup-tw.com/

Guide of Control Valve Actuator: Types and When to Use The Right Valve Actuator?

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When scaling out a new control valve, vendors should support with every specification and recommend the right device for the application. Also, what is important to know is which type of control valve actuator is actually needed.

 

This article will tell you all you need to know about control valve actuators, the part of a control valve that receives commands from the control system to create a force that moves a control valve. Control valve actuators do this either directly or through a control valve positioner, which converts digital or analog signal to pneumatic output.

 

Types of Control Valve Actuator

There are five commonly used control valve actuator types. So let’s take a quick look at each.

 

  • Pneumatic Control Valve Actuator

This type has a flexible diaphragm with pressure applied against the force of the actuator spring. When the control system sends its signal, the actuator creates a force that overcomes the force of the spring, moving the actuator stem.

 

We have two types of action in a pneumatic actuator: direct and reverse. Direct action means the actuator pushes the stem down and the spring pushes it up. Reverse action will move the stem up, and the spring moves it down.

 

  • Pneumatic Control Valve Piston Actuator

This works much like an actuator with a diaphragm and spring. However, this actuator replaces the diaphragm with a piston. We have two types of action here too: linear and rotating. Linear moves the actuator component in a straight line and rotating turns it.

 

  • Electric Control Valve Actuator

This actuator has a motor and gearbox to create torque that moves the valve up and down. We can find this electric control valve actuator in linear and rotating control valves.

 

  • Electric-Hydraulic Control Valve Actuator

This type mixes electric signals and hydraulic units to act on the valve. The signal will control the flow of oil to open and close the valve, using a flapper-nozzle system similar to a pneumatic system.

 

  • Hydraulic Control Valve Actuator

This works much like a pneumatic actuator, and we can use it in linear and rotating control valves. However, it uses fluid rather than air to create force in its system.

 

If you have interest and requirement of electric control valve actuator or other valve actuators, I recommend you to visit Sun Yeh Electrical Ind. Co., Ltd. – they specialize in manufacturing kinds of electric actuators. Today, contact with Sun Yeh for more details!

 

Article Source: Visaya

Guide of Face Mills: Types, Specifications, and Materials

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Face mills are primarily used for milling a face on the surface of a plate or bar. They are predominantly used to cut with the ends of the cutter rather than their sides. The term “face” refers to the creation of a flat face on the workpiece. Face mills often have a larger diameter than the width of the workpiece being faced, so that the surface can be processed in one pass.

 

Types

Face mills may be of solid construction or with holders and inserts. They can be used with a number of end or tip geometry options, including square end, ball nose, radius tip, and chamfer tip.

 

  • Square end tip geometry for face mills have a square or straight end that features no radius, chamfer, or other finish.
  • Ball nose face mills tips have a “ball nose” whose radius is one half of the cutter diameter. This type of face mills tip is useful for machining female semicircle grooves of radii.
  • Radius-tipped face mills ends are straight flutes with ground radius on the very tip.
  • Chamfer tip ends feature an angled section of the side or the end. These tips produce an angled cut of chamfered edge on a workpiece.

 

Specifications

When selecting a face mill, consideration must be made to the desired finish type. There are typically two finish options: roughing/hogging and finishing. Roughing/hogging mills are designed so that the machine geometry, flutes, and materials can be used for rapid and heavy material removal. They are typically used to machine workpieces close to the desired finishing dimensions, where a finishing face mill takes over and produces closer tolerances and higher-quality surface finish.

 

Other considerations for face mills include cutter size and construction criteria. Size considerations for face mills relate to the:

 

  • Cutting Diameter
  • Shank Or Arbor Diameter
  • Flute Or Cutting Edge Length
  • Overall Tool Length
  • Radius Dimension And Angle

 

Construction options for face mills include the number of flutes of cutting edges. This number can vary with the cutter diameter, milling material, and other factors. Two-flute face mills are often used with ductile materials that produce long chips. Face mills using a higher-number of flutes can be used to minimize chip load and vibration.

 

Materials

The material of the face mill is important for understanding the level of cutting the machine can handle. Materials like carbide, cobalt, and diamond are hard and can be used in high-speed applications, whereas materials like steel are used for general metal machining. Other material options for face mills include micrograin carbide, which is used most-often in surface finishing applications, and ceramic.

 

Coatings for face mills are important considerations as well, as they can provide additional protection against corrosion and abrasion, increase the tool’s hardness, provide lubrication and smoothness assistance, and improve the overall lifetime of the tool. Other considerations and options for face mills may also be available depending on the manufacturer.

 

If you have requirement of face mill arbors and much more tool holders, I recommend you to visit ANN WAY Machine Tools Co., Ltd. – they are the manufacturer of specializing in various cutting holders and cutting tools. Today, contact with ANN WAY for more details of face mill arbors!

 

Article Source: https://www.globalspec.com/learnmore/manufacturing_process_equipment/cutting_forming_tools/face_mills

How to Choose The Right Power Cords?

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With today’s need for electronic equipment, manufacturers are realizing that in order to prosper—and in some cases to survive—they may have to export to global markets. When designing for global markets, a number of factors are involved, such as being able to provide equipment that is easily adaptable to the needs of the consumer, without any reconfiguration on their part.

 

One of the main considerations is to ensure the end-user has the correct means of connecting to their local mains supply. It’s also important to follow standards and country-specific regulations. Choosing the right components in the product design is essential as is identifying them in ways that others can understand.

 

Choosing a Power Cord or Cord Set

 

The selection of the appropriate power cord or cord set is an important step for equipment designers to ensure that their product may be used worldwide. Choosing a cord usually involves four steps:

 

  1. Identify The Correct Plug For The Country Of Export

The first choice concerns the plug pattern for the country of export. As there are a number of plug patterns used throughout the world, determining the correct one is essential. When deciding on the correct plug pattern, keep in mind that while some look similar that does not mean it is the right cord for the equipment.

 

  1. Determine The Rating Of The Power Cord Or Cord Set

In order to choose the correct power cord or cord set, it’s crucial to know the amperage and voltage rating that is required for the equipment being exported. Higher or lower amperage can mean a different plug pattern, even in the same country. Amperage requirements also affect the cable size.

 

  1. Choose The Correct Cable

Again the country of export for the product matters when choosing the cable. There are differences between North American and international cable and they are not interchangeable. North American cable cannot be used in countries where international cable standards are in place and vice-versa.

 

  1. Choose The Correct Connector, If Utilizing A Cord Set

Choices for a connector may include an IEC 60320 connector or an inline country-specific socket. An advantage of using IEC 60320 components is that they can assist in making a product globally accessible.

 

If you have requirement or need more information of various power cords, you can come and visit King Fortune Electrical Co., Ltd. – they not only provide industrial fans but also power cords and various fan parts. Today, contact or send inquiries to King Fortune for more details!

 

Article Source: Interpower

What Is a Spring Return Actuator?

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A spring return actuator is a control device that supplies one-way powered motion with the impetus for its return stroke being supplied by a spring. For example, a spring return door actuator will only open the door under its own power with the door being closed again by a spring arrangement. The simple solenoid is a good example of a spring return actuator, with the solenoid plunger being returned to its neutral position by spring tension. The fact that the actuator only supplies a single-powered stroke simplifies the actuator control system with commensurate reductions in unit cost and maintenance requirements. The spring return actuator typically has a longer service life, further enhancing the cost savings on such systems.

 

Conventional bi-directional actuators supply powered actuation force for both their working and return strokes. This is typically achieved by reversing the direction of an electric motor or, in the case of hydraulic and pneumatic systems, pumping compressed oil or gas into the opposite side of the actuator cylinder. In contrast, a spring return actuator only utilizes a powered stroke on one-half of its working cycle. The impetus for the return stroke that resets the mechanism to its neutral position is supplied by a spring arrangement. One of the best examples of this concept is the linear solenoid that uses a spring to return its plunger once power is cut to the coil.

 

There are many types of spring return actuator mechanisms available for both linear and rotary output applications. In some cases, the return spring is an integral part of the actuator mechanism and, in others, a separate unit. The rate at which the return spring moves the secondary mechanism is often governed to produce a specific reset speed. In many cases, this governing function is achieved courtesy of a separate hydraulic damper typically fitted with an adjustable damping valve mechanism, allowing for fine-speed settings to be made.

 

The single powered stroke of a spring return actuator holds several benefits, including low installation costs, long service life, and reduced maintenance. The benefits can be attributed to the relative simplicity of the systems and the reduced number of control elements and duty cycles required for their operation. This means slightly lower initial costs and reduced running expenses. It also ensures superior longevity of the actuator and its power supply as only half of the normal duty cycles performed for each actuation.

 

If you have interest in spring return actuators, I recommend you to visit Sun Yeh Electrical Ind. Co., Ltd. – they are the professional electric actuators supplier in Taiwan. Today, contact with Sun Yeh for more details of spring return electric actuators.

 

Article Source: https://www.wisegeek.com/what-is-a-spring-return-actuator.htm

Scaffolding Best Practices You Might Not Know

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The term “little known,” is subjective at best. Many of you being in the construction industry, maybe very well aware of most of these OSHA guidelines for safe scaffolding. What I will try to do in this article is to address both things that are commonly found on any construction site and not so obscure that it would never be utilized.

 

For starters, any scaffold should have a base of some sort. An “adequate foundation” is what OSHA says that every scaffold must have. There are many different foundations out there; there could be dirt, rock, mud, water, asphalt, grass, a roof, a metal top to a tank or concrete. Scaffolds can be built on catwalks, on the space shuttle and anything else that someone may have to work on.

 

In other words, you can’t take a frame scaffold and just set it on the ground or even on concrete. It must have a base plate or screw jack at a minimum. Even with a base plate or screw jack, it also needs a wooden mud sill if it’s going to be setting on dirt, gravel, grass etc. The only foundation that does not need a mud sill is concrete. Every other foundation must have a base plate or screw jack and mud sill.

 

That brings us to screw jack height. This is a common question that many people don’t actually know the answer to. It is suggested many times that a screw jack can only be raised 12 inches. This is actually not correct. Each manufacturer designs his screw jack differently, and some design them so that they can be raised higher than 12 inches. You must check with the manufacturer of the screw jack that you are specifically using. Some are designed to be raised 18 inches and many have a notch or a weld towards the top of the jack which is its maximum raising height and prohibits you from screwing the Jack any higher past that notch.

 

“It’s close enough.” There’s no such thing as close enough when it comes to getting the scaffold level. Scaffolds must be exactly plum and exactly level for it to be considered safe. Even if the scaffold is only out of level by a very small amount, it is not considered safe. When the scaffold is at a greater height, it will be leaning out of plum at a much greater degree. Cross braces will not go on as easily or at all, and if the scaffold is leaning out of plum and a load is set on top the chances of it overturning are dramatically higher. Every scaffold must be absolutely level.

 

Platform Construction

One thing that I often see and I’m sure not as many people know as there should be, is that there is only supposed to be 1 inch or less gap between scaffold boards. This is for several reasons, but one main reason is so that small items like wrenches, wall ties, jointers, etc. will not fall through the gap and strike someone below.

 

Another interesting tidbit about platform construction is that one scaffold board is not permissible to work from. OSHA regulations state that any scaffold must be at least 18 inches wide. There may be exceptions if there was absolutely no other way to erect the scaffold, but you must be able to prove that.

 

An additional fact that all of our readers should know is that the out-rigger scaffold is supposed to be a maximum of 3 inches away from the wall. Again, it’s for more than one reason, but the main one is because there are no handrails next to your out-rigger facing the masonry wall that you’re working on, therefore they want the wall in front of you and less chance of falling on that side the scaffold.

 

Here’s one that you may not know; if a board is 10-foot-long or less you cannot have more than 12 inches of the end of the board over it support. Also, if it is a scaffold board greater than 10 feet, you can have no more than 18 inches over its hand support or there must be guardrails so that someone cannot walk out on the end of those cantilevered boards, they tip up and a person falls.

 

A Couple of Points About Scaffold Access

Any scaffold that requires someone to step up more than 24 inches should have a ladder utilized to access the scaffold. The first rung or bottom rung of the ladder must be a maximum of 24 inches from the ground or walking working surfaces. That height for the first rung is actually quite high, and most people prefer sitting the ladder on the ground so they’re not required to have such a tall first step. Another thing that most people that are reading this are aware of is that the ladder must reach at least 3 feet above the scaffold platform.

 

Another item that should be noted is that you never increase the scaffold height by adding boxes, barrels, concrete block, brick etc.… to the platform. This includes ladders, such as extension ladders or step ladders. OSHA does allow a ladder to be used on top of the scaffold if many stipulations are met, but this is not a suggested practice.

 

Guardrail System

In closing we cannot talk about safe scaffolding without bringing up the guardrail system. Every system must include a top rail and mid rail. They should be installed on all open sides of the scaffold. The top rail should be able to withstand 200 pounds of downward and outward force placed upon it. That means if you’re a big fellow and way more than 200 pounds, it’s probably not a good idea to lean all over the handrail.

 

Another thing that should always be maintained is the proper height of the top rail. OSHA gives a little leeway in the top rail; it can be between 38 and 45 inches in height. Another not so commonly-known allowance is that a cross brace can be used for a mid-rail if the crossing point of the brace is between 20 and 30 inches above the platform and the ends of the cross brace are no more than 48 inches apart.

 

Now, hopefully you already knew all of this, but as you know, the three steps to remembering are Repetition, Repetition, Repetition!

 

To have safe scaffolding, I recommend you a professional scaffold manufacturer – Sucoot Co., Ltd... They specialize in manufacturing industrial scaffolding accessories & formwork parts. If you need more information of scaffolding parts, welcome to contact with Sucoot for more details!

 

Article Source: https://www.masonrymagazine.com/blog/2017/01/01/scaffolding-best-practices-might-not-know/

The Advantages and Disadvantages of Diamond Grinding Wheel

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Besdia Diamond Grinding Wheels

Diamond grinding wheels made of diamond or cubic boron nitride (CBN) are widely used in various aspects of the grinding field because of their excellent grinding performance. Diamond grinding wheel is a special tool for grinding hard alloy, glass, ceramics, precious stones and other hard brittle materials.

 

With the rapid development of high speed grinding and ultra-precision grinding technology, the grinding wheel put forward higher requirements, ceramic and resin bonded diamond has been unable to meet the needs of all production metal bonded grinding wheel due to the combination of high strength, good formability, long life and other significant characteristics in production in the extensive application.

 

Metal bonded diamond grinding wheels are mainly produced by two types: sintering and electroplating. In order to give full play to the role of abrasive, foreign from the early 1990s began to develop a new type of grinding wheel for high-temperature brazing process, namely the brazed monolayer super hard abrasive grinding wheel, at present the wheel is still in development stage.

 

Sintered diamond grinding wheel sintered metal bonded grinding wheel more to bronze and other metals as binder, made by the high temperature sintering method, combined with their high strength, good formability, high temperature resistance, thermal conductivity and good wear resistance, long life, can bear larger load.

 

Because the grinding wheel in sintering process is inevitable in the shrinkage and deformation, so before the use of the grinding wheel must be plastic, but the grinding wheel dressing is more difficult. At present, the grinding wheel which is commonly used in the production process is not only time-consuming and laborious in dressing process, but also the loss of diamond particles is more in the process of dressing.

 

If you have interest or requirement of diamond grinding wheels, I recommend you to visit Best Diamond Industrial Co., Ltd. – they are the manufacturer of specializing in various diamond and CBN tools. Now, check out their website and contact with Besdia for more details!

 

Article Source: http://www.jrdiamondtools.com/en/news/2016-7-2/244.html

What Products Can Be Made from Injection Molding?

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The process is highly versatile and can produce a myriad of parts for a wide variety of applications.

 

When creating a product that requires molded plastic parts, depending on the type of application and type of part you want to produce, you have several processes to choose from. One of the most popular processes to achieve high quality and cost effective plastic parts is injection molding.

 

Injection molding is a manufacturing process for producing parts in large volume – from thousands to millions. Melted resin is injected into a hollow mold until it is completely filled. The injection molding process uses high temperature and extreme pressure to sufficiently fill the interior with molten plastic resin or liquid polymers. The molds are then cooled to release completed plastic parts.

 

The process is highly versatile and can produce a myriad of parts for a wide variety of applications.

 

Typical Products Made with Plastic Injection Molding

Plastic Bottles are the most common product manufactured by the billions each year, ranging in multiple shapes and sizes. Typically, the plastic bottles used to hold potable water and other drinks are made from polyethylene terephthalate (PET), because the material is both strong and light.

 

Electronic Housings are also quite commonly fabricated with injection molding services. Used in devices such as remote controls, computers, televisions, medical equipment, and other consumer electronic components, housings are all produced by injection molding process. Injection molding services can manufacture any custom plastic enclosures for practically any application and sizes.

 

Toys: Imagine a building material which is lightweight, durable, and doesn’t corrode; it comes in many sizes and colors and is designed for easy precise assembly. The Lego brand of building block recognized by all is made of firmer plastic granules which are heated until liquefied and then injected into metal molds in which the plastic cools and solidifies into a studded brick or other shape. But what’s important is that each brick and component is accurately molded so they’ll all fit together. It’s a precision product available in many colors, shapes, and sizes.

 

Agricultural: OEMs designing for the agricultural marketplace are switching to plastic as a low cost alternative to metal components commonly used throughout the industry. Plastics offer higher resistance to impacts during use, humidity, and are able to resist extreme high or low temperatures. UV additives also help protect plastic parts from harsh weather conditions or exposure to corrosive substances.

 

Household: Molded closures, containers, components, and drinkware are just a few of the common items that can be custom fabricated with injection molding.

 

Machinery and Automotive Components: Bumpers, dashboards, radio controls, cup holders, and many other elements found in cars and transportation vehicles, both interior and exterior, are made by the injection molding process.

 

Healthcare Industry: In the healthcare field, there are thousands of products that are made with the injection molding process. The healthcare industry relies heavily on multipurpose plastic products that can be manufactured in bulk, as many of these products are single use, disposable items to maintain sterility or to prevent the spread of germs or disease. From plastic syringes to tools used in medical procedures, injection molding is what helps the medical professionals get their jobs done.

 

Injection Molding is a very common manufacturing method used to produce everyday household items. The applications cover commercial, industrial, and consumer products alike. Injection molding offers the versatility to generate designs that have intricate detail or complexity, down to simpler forms in any range of sizes from small to large objects.

 

This method has produced solid parts such as electronic housings, bottle caps, containers, computers, televisions components, bag accessories, outdoor furniture, agricultural products, toys, machinery components, and much more.

 

If you need plastic injection molding services, I recommend you to visit Shin Fang Plastic Industrial Co., Ltd. – they are the experienced manufacturer of specializing in various plastic injection products. Now, check out their website for more details of plastic injection moulding.

 

Article Source: https://www.ien.com/product-development/article/21014543/what-products-can-be-made-from-injection-molding

CNC Guide: Best Design Practices for Custom CNC Machining Parts

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Here’s a good refresher on common practices to keep manufacturability and cost in mind when designing a part.

 

What exactly is computer-numerical-controlled (CNC) machining? It’s a means to make parts by removing material via high-speed, precision robotic machines that use an array of cutting tools to create the final design. CNC machines commonly used to create the geometric shapes required by customers are vertical milling machines, horizontal milling machines, and lathes.

 

To successfully make a part on a CNC machine, programs instruct the machine how it should move. The programmed instructions are encoded using computer-aided-manufacturing (CAM) software in conjunction with the computer-aided-design (CAD) model provided by the customer. The CAD model is loaded into the CAM software and tool paths are created based on the required geometry of the manufactured part. After determining the tool paths, the CAM software creates machine code (G-code) that instructs the machine on how fast it should move, how fast to turn the stock and/or tool, and the location to move in a 5-axis coordinate system.

 

Complex cylindrical shapes can be manufactured more cost-effectively using a CNC lathe versus a 3- or 5-axis CNC milling machine. With a CNC lathe, cutting tools are stationary and the part stock is turning, whereas on a CNC mill, the tool turns and the stock is fixed. To create the geometry, the CNC computer controls the rotational speed of the stock as well as the movement and feed rates of the stationary tools required to manufacture the part. If square features need to be created on a round part, the round geometry is first created on the CNC lathe and then the square features would be made on a CNC mill.

 

Because the computer controls the machine movement, the X, Y, and Z axes can all move simultaneously to produce a range of features, from simple straight lines to complex geometric shapes. Some limitations do exist in CNC machining, and not all shapes and features can be created even with the advances made in tooling and CNC controls. The limitations will be discussed later.

 

General Tolerances

If a drawing or specification sheet has not been provided by the customer, a company may provide general specifications to follow to manufacture a model. These specifications may change from one company to another. In addition, some companies do not have default tolerances and will require the customer to provide the specifications.

 

Part Tolerances

Tolerance is the acceptable range for a dimension, which is determined by the designer based on the form, fit, and function of a part. It is important to keep in mind that a tighter tolerance can result in additional cost due to increased scrap, additional fixturing, and/or special measurement tools.

 

Longer cycle times can also add to the cost if the machine needs to slow down to hold tighter tolerances. Depending on the tolerance call out and the geometry associated with it, costs can be more than double of what it would be to hold the standard tolerance. Tighter tolerances should only be used when it is necessary to meet the design criteria for the part.

 

Furthermore, overall geometric tolerances can be applied to the drawing for the part. Based on the geometric tolerance and type of tolerance applied, cost may rise due to increased inspection times.

 

The best way to apply tolerances is to only apply tight and/or geometric tolerances to critical areas, which will help minimize costs.

 

Size Limitations

 

Milling

Part size is limited to the machine’s capabilities and depth of cut required by a feature in the part. Keep in mind that a build space’s dimensions don’t equate to part size. The features and size of the part will determine the part’s machinable height.

 

Lathe

Lathe capabilities will depend on the build space, or the diameter and length. A company may also offer a live tooling lathe, which dramatically decreases lead times and increases the amount of features that can be machined by combining additional CNC milling functions within the lathe.

 

Material Selection

Material selection is critical in determining the overall functionality and cost of the part. The designer must define the design’s important material characteristics—hardness, rigidity, chemical resistance, heat treatability, and thermal stability, just to name a few.

 

Metals

As a general rule, softer metals, like aluminum and brass, as well as plastics, machine easily and will take less time to remove material, which in turn reduces time and cost. Harder materials, like stainless steel and carbon steel, must be machined with slower spindle RPMs and machine feed rates, which would increase the cycle times versus the softer materials. As a general rule, aluminum will machine about four times faster than carbon steel, and eight times faster than stainless steel.

 

Plastics

Plastic material can be a less expensive alternative to metals if the design doesn’t require the rigidity of metal. Polyethylene is easy to machine, and costs about 1/3 that of 6061 aluminum. In general terms, ABS is about 1½ times the cost of Acetal; nylon and polycarbonate are approximately three times the cost of Acetal. Keep in mind that depending on the geometry, tight tolerances can be harder to hold with plastics, and the parts could warp after machining because of the stress created when material is removed.

 

Complexity and Limitations

The more complex the part, which means contoured geometry or multiple faces that need to be cut, the more costly it is due to additional setup time and time to cut the part. When a part can be cut in two axes, the setup and machining can be accomplished faster, thus minimizing the cost.

 

For simple two-axis parts, more material will be removed as the tool moves around the part than with a contoured part. With a more complex part, some areas will need to be cut with X, Y and Z axes moving together.

 

To create a complex surface with a good surface finish, very small cuts will need to be used. This increases the time and, therefore, price of a part. A general rule to help minimize the cost is to try and design using only two axes cuts, but this isn’t always possible if a certain look or functionality is required. Keeping things consistent, such as internal corner radii and tapped holes, will also help save time and money on parts by reducing the need for tool changes.

 

Five-Axis Machining

Five-axis machining capabilities allow for more complex CNC machining parts to be manufactured in the most cost-effective manner. Five-axis machining means that the machine and the part can be moved in up to five ways simultaneously around multiple axes. The coordinated movement allows for very complex parts to be manufactured more efficiently because it minimizes setups, attains faster cutting speeds, generates more efficient tool paths, and achieves better surface finishes.

 

By using five-axis technology versus conventional three-axis machining, fewer setups are required to create a part with complex geometry. With three-axis milling, contoured parts, or parts with machining on several faces require multiple setups to create the geometry. Oftentimes, with three-axis machining, complex fixtures must be made in order to hold a part in the orientation necessary to create the feature. Five-axis machining eliminates the need, and thus cost, of creating the fixtures, because the part can be held once and rotated to create complex geometries.

 

Finally, by using a five-axis capable machine, the machine and part movement allows for the cutting tool to remain tangential to the cutting surface. Lower cycle times and costs are achieved because more material can be removed with each pass of the tool, and better surface finishes result by using the five-axis capabilities on contoured geometry. In traditional three-axis machining, very small cuts must be used to create a good surface finish, resulting in longer lead times.

 

If you have requirement of CNC machining parts, I recommend you to visit Sharp-eyed Precision Parts Co., Ltd.

 

They focus on the development as well as machining of a modern extent of complex CNC precision machinery parts made with coordinating focuses. Supplied in various particulars to look around, these precision parts are generally developed according to customer aspect. More than 30 years’ connection with designing and producing lots of precision machining parts, their CNC precision machining parts are for customers overseas and locally. Now, contact with Sharp-eyed for more details!

 

Article Source: Machine Design

The Aluminum Die Casting Process and The Growth of Die Casting Industry

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The casting process implements a steel mold often capable of producing tens of thousands of castings in rapid succession. The die must be made in at least two sections to permit removal of castings. The casting cycle begins with the two die halves are clamped tightly together by the die casting press. Molten aluminum is injected into the die cavity where it solidifies quickly. These sections are mounted securely in a machine and are arranged so that one is stationary while the other is moveable. The die halves are drawn apart and the casting is ejected.

 

Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting. Most machines use mechanisms actuated by hydraulic cylinders to achieve locking. Others use direct acting hydraulic pressure. Die casting machines, large or small, very fundamentally only in the method used to inject molten metal into the die.

 

What Are The Advantages Of Aluminum Die Casting?

There are many reasons aluminum is the most commonly cast non-ferrous metal in the world. As a lightweight metal, the most popular reason for utilizing aluminum die casting is that it creates very lightweight parts without sacrificing strength. Aluminum die casting parts also have more surface finishing options and can withstand higher operating temperatures than other non-ferrous materials.

 

Aluminum die cast parts are corrosion resistant, highly conductive, have a good stiffness and strength-to-weight ratio. The aluminum die casting process is based on rapid production that allows a high volume of die casting parts to be produced very quickly and more cost-effectively than alternative casting processes. Aluminum die casting has become the favored option for buyers worldwide. Characteristics and Advantages of Aluminum Die Castings include:

 

  • Lightweight and Durable
  • Good Strength-to-Weight Ratio
  • Great Resistance to Corrosion
  • Excellent Electrical Conductivity
  • Fully Recyclable and Reusable in Production

 

Aluminum Die Casting Product Segmentation

The popularity of aluminum has expanded to many applications around the world today, driving competitive market shares primarily for its distinctive features such as lightweight; corrosion resistance, high electrical and thermal conductivity, high stability for complex shapes and high tensile strength. The transportation sector is the largest end-use segment for this industry. The increasing emission laws by the government regulatory authorities, along with consumer demand for a higher fuel-efficient vehicle is developing a necessity for aluminum casting. An example of increased operations for the industry includes the replacement of iron and steel components in a vehicle with lightweight high-quality aluminum in order to increase the fuel efficiency. The aluminum die casting product is ideal for electronic connectors and housings die to its excellent electrical performance and shielding properties, even in high-temperature environments.

 

Another sector regarding the aluminum die casting demand includes building and construction in developing economies particularly in the Asia Pacific region. Aluminum Die Casting is associated with the creation of products including windows, cladding, curtain walling, prefabricated buildings, shop partitions, and fittings. Also, aluminum die casting products are used in aerospace operations or airplanes all around the world. The aerospace industry wants to produce a denser and larger quality product at lower costs for these air-frame components as aircraft continue to grow in size along with population rates.

 

According to Transparency Market Research, the Asia Pacific region accounts for over the half the share in the global market for aluminum castings. In the years ahead, the region is expected to further increase its share by pulling in the maximum Compound Annual Growth Rate of 5.3% during the forecast period between 2017 and 2025, and the powerhouse of China taking most of the credit. This market region is expected to become US $22.67 bn by 2025. Another important driving force includes the regions of Europe and North America in the global market for aluminum castings. While Europe is expected to register a Compound Annual Growth Rate of 5.1% during the forecast period to become worth US $9.45 bn, and the North America regions is expected to rise at a Compound Annual Growth Rate of 4.9% to become worth US $4.22 bn by the end of the year 2025. The statistics provided in this article express the importance in future Aluminum Die Casting growth for global production needs.

 

If you have requirement of aluminum die casting parts, I recommend you to visit Champion H&C Inc. – they are the professional aluminium die casting manufacturer in Taiwan. With years of experience, they can provide and custom best-quality die casting products for customers. Now, contact with Champion H&C to get more information of die casting services!

 

Article Source: https://www.phbcorp.com/what-is-aluminum-die-casting/