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What Is Grinding Machinery?

Grinding machinery (grinder) is a machine tool for precision finishing by grinding the surface of a workpiece by bringing the workpiece into contact with a grinding wheel rotating at high speed. There are many types of grinders, depending on the combination of the motion of the grinding wheel and the workpiece. There are many types of grinders, such as for inner and outer diameters of cylinders, for flat surfaces, and for gears.

Grinding machinery is characterized by its ability to machine even hard materials such as hardened steel and special alloy steel, which are difficult to machine by ordinary cutting methods. Those that perform machining by precisely adjusting the machining volume through machine operation are called mechanical grinding machinery, and are distinguished from free grinding machinery, the so-called grinders.

Uses of Grinding Machinery

Grinding machinery is mainly used for finishing the surface of workpieces. After primary and secondary machining to shape and precision by cutting, grinding is performed to finish the dimensions and surface properties of the workpiece with even higher precision.

Examples include crankshafts, camshafts, gears, screws, splines, tools, jig grinding, and rollers. They are also used for processing glass, jewelry, and ceramics.

Principle of Grinding Machinery

Grinding machinery uses a grinding wheel to remove the surface of the workpiece for high-precision machining. The grinding wheel used is made of abrasive grains solidified with a bonding agent, and has numerous pores inside. The abrasive grains act as cutting edges during machining, and they peel off from the bonding agent during machining and are discharged together with chips.

Grinding machinery can produce very clean work surfaces because the stripping and ejection process is constantly repeated and new abrasive grains are always used. Grinding machinery performs high-precision machining with a very small depth of cut. Since grinding is done repeatedly with a high peripheral speed grinding wheel, a large amount of heat is generated.

For this reason, the grinding wheel is continually cooled by pouring a processing fluid or other means. Grinding Machinery requires only a small depth of cut, so it has the disadvantage of taking longer machining time than other machining methods.

Types of Grinding Machinery

There are several types of grinding machinery depending on the purpose of grinding and the shape of the workpiece.

1. Surface Grinding Machinery

The workpiece is fixed to a table that moves in the front-back and left-right directions. The flat surface of the workpiece is then ground with a rotating grinding wheel. 

2. Cylindrical Grinding Machinery

The periphery of a cylindrical workpiece is ground. The workpiece is moved left to right and the grinding wheel is moved up and down. Both the grinding wheel and the workpiece are rotated at high speed while grinding the outer circumference. 

3. Internal Grinding Machinery

The internal surface of a cylindrical workpiece is ground. The fixed workpiece is rotated at high speed and grinding is performed with a grinding wheel inserted into a hole in the workpiece.

4. Centerless Grinding Machinery

Centerless grinders grind cylindrical or cylinder-shaped workpieces and are also called a centerless grinding machinery. The workpiece is ground by placing it between two grinding wheels with different rotation speeds. Since the workpiece can be moved in the axial direction for continuous operation without being fixed, it has the advantage of higher productivity.

Other Information on Grinding Machinery

1. Grinding Machinery Grinding Wheels

A tool called a grinding wheel is required for the grinding process using a grinding machinery. The grinding wheel has three elements: abrasive grains, bonding agent, and pores. The abrasive grains are used to scrape away the abrasive grains and worn abrasive grains naturally drop off and new abrasive grains appear on the surface.

The abrasive grains work to scrape the object. The bonding agent binds the abrasive grains and adjusts the performance of the grinding wheel. Pores help to discharge chips to prevent clogging and to reduce the heat generated by the grinding wheel.

Abrasive grains are particles of hard materials used to cut metals and difficult-to-cut materials. Alumina (aluminum oxide) and silicon carbide are generally used. Alumina is used for grinding steel and nonferrous metals, while silicon carbide is used for nonferrous metals. Diamond or CBN (cubic boron nitride) abrasive grains are used for hard-to-cut materials.

The bonding agent is an adhesive used to harden abrasive grains. There are three types of bonding agents: ceramic-based, resin-based, and metal-based. Select a grinding wheel made of the material that best suits the processing purpose, such as “vitrified” (ceramic-based) for precision grinding, “resinoid” (resin-based) for a wide range of grinding and finishing operations, and “metal” (metal-based) for rough grinding and cutting. 

2. Chuck of Grinding Machinery

The chuck used to attach the workpiece to the grinding machinery depends on the type of grinding machinery. Surface grinding machinery is used to cut rectangular materials, so the chuck is a table type. The workpiece is fixed by sucking it with a magnetic chuck, such as a magnet or a vacuum chuck.

In the case of cylindrical grinding machinery, both centers of the material are fixed in place in order to process a cylindrical workpiece to reduce its diameter. In the case of an internal grinding machinery, the end of the material is attached to a three- or four-jaw chuck, as on a lathe, for machining.

What Is an Ultrasonic Cutting Machine?

An ultrasonic cutting machine is a device that uses ultrasonic waves to perform cutting and polishing operations. Cutting oil or abrasive slurry is applied between the ultrasonically vibrating tool and the workpiece, causing the surface of the workpiece to undergo brittle fracture and material removal gradually. Ultrasonic processing machines consist of a transducer that vibrates ultrasonically, an oscillator that drives the transducer, and a cutting tool.

Ultrasonic machining is one of the few machining methods that can process three-dimensional shapes of brittle materials, even if the materials are not conductive.

Applications of Ultrasonic Machining Tools

Ultrasonic machines are used to process brittle materials and materials that are difficult to process by general machining. Examples include cutting hard ceramic and metal materials, cutting hard-to-cut carbon fiber, processing quartz glass, and polishing molds.

In addition to hard materials, ultrasonic processing machines are also used for cutting cakes and pie crusts that easily lose their shape, slicing bread, and cutting pizza into pieces, which are commercialized as ultrasonic food cutters. The microscopic ultrasonic vibration reduces frictional resistance between the blade and the food, resulting in a clean-cut surface.

Principle of Ultrasonic Processing Machines

Ultrasonic processing machines apply ultrasonic vibrations to blades to reduce cutting resistance and achieve high processing speed and high precision cutting. There are several ultrasonic machining methods, including cutter and grinding, but the principles of typical methods are explained here.

In spindle machining, ultrasonic vibration is applied to the machining jig, and the jig is rotated for machining. In abrasive grain processing, abrasive grains are poured into the ultrasonically vibrating processing jig, and then ground and processed in small quantities.

The following is a brief description of the oscillator and transducer that make up the ultrasonic processing machine. The oscillator converts electric power into ultrasonic vibration. Since the operating frequency of the transducer varies with the blade and grinding wheel, it is equipped with an electronic circuit to adjust it to the optimum frequency.

The transducer consists of a bolted Langevin-type transducer (commonly called BL transducer) that generates ultrasonic vibration, a fixed horn that increases the amplitude, and a blade that transmits the vibration. There are several types of blades depending on the application, and they are used according to the situation.

What Is a Machine Vise?

A machine vise is a jig that is attached to a table or machine to hold the object in place so that it does not move when processing metal plates and other materials. They are mainly used for processing, such as milling, grinding, and drilling. By using a machine vice to precisely and strongly fix an object, the X, Y, and Z axes can be made accurate and the accuracy of machining can be improved.

However, a powerful load is applied during machining, so care must be taken to avoid lifting even when using a machine vise.

It is important to select a machine vise that is compatible with the machine to be processed, such as a milling machine or machining center.

Usage of Machine Vises

Machine vises are used to fix objects in machining centers and milling machines. In most cases, machine vises are clamped to a table, etc. Some models are fixed to an electromagnetic chuck for precision machining, while some models are equipped with a function to prevent lifting during machining.

There are machine vises made of cast iron to withstand powerful work, and other materials to suit the application. Machine Vises are also available in sizes ranging from small to large, depending on the object to be processed.

Principle of Machine Vises

Screws or shafts are used to clamp and secure the object to the table or equipment. There are two types of fixing methods: handle-type and wrench-type.

In the handle-type, once the object is clamped in the machine vise, simply turn the handle to secure it in place.

In the wrench-tightening type, the object is clamped in the machine vise, and the shaft is fixed in the groove hole on the side by turning the wrench and moving the movable mouthpiece.

Take care that the object is clamped in a slightly loose position and that the shaft is properly seated in the groove hole. As you tighten the rod bolt, the shaft acts as a fulcrum to pinch and secure the object. Tightening the rod bolt when the shaft is just caught in the groove hole may cause failure.

Normally, a machine vise is clamped to a table, but there are cases where a machine vise is fixed on a milling machine using an electromagnetic chuck.

The machining direction is usually one direction, but with models such as a sign vise with an inclination, a two-dimensional vise in which the vise itself rotates, and a three-dimensional vise, you can set the machining direction by yourself.

What Is a Painting Robot?

Painting robots are industrial robots used for painting.

Most painting robots are equipped with a painting gun attached to an articulated arm to handle delicate painting tasks. Painting robots can reduce the risk of health hazards caused by organic solvents contained in paints when painted by humans.

Painting Robots can also improve productivity and reduce human error and variation. In fact, in a roof Painting Robot case study, productivity was increased by a factor of 35, and the use of robots in industry is rapidly increasing.

Applications of Painting Robots

Painting Robots have been introduced in the automotive industry and many other manufacturing sites where painting is required. A wide range of sizes, from large ones for automobiles to small ones for electronic components, are now available on the market, and their introduction is further expanding.

Since production is more stable than when done by humans and human health hazards can be reduced, it has also begun to be introduced in the fields of roofing, wall construction, daily necessities, and various parts. In some cases, Painting Robots are being used in the traditional craft of lacquerware.

Principle of Painting Robot

Painting Robot consists of an industrial robot with a painting gun attached. Since the paint sprayed during painting also splashes on the robot itself, explosion-proofing was an issue.

Many robots are articulated with 5 to 6 axes, and the following three types of robots are mainly used:

1. Vertically Articulated Robots

Vertically articulated robots have 5 to 6 axes of vertically rotating joints and can move in a manner similar to a human arm in appearance. By changing the direction of the axes, the robot can rotate not only vertically but also diagonally. It can also be used for painting complex shapes.

2. Horizontal Articulated Robot

Joints and links are connected horizontally, and rotation is possible in the horizontal direction. Since the robot moves almost exclusively in the horizontal direction, it is suitable for coating flat objects.

3. Rectangular Coordinate Robot

This robot has a structure in which three axes slide and move, and is also called a Cartesian Coordinate Robot. Since they cannot perform complex movements, they are suited for objects with simple shapes.

Other Information on Painting Robots

1. Examples of Painting Robot Applications

Introduction of Wall Spray Painting Robot
The distance between the wall and the Painting Robot is measured by a distance sensor, and the robot’s position is controlled to maintain the distance at a constant level. This technology ensures uniform distribution of the coating volume and quality equivalent to that of skilled workers.

It is also possible to use “human-robot collaboration,” in which the robot is semi-automated and a person works in the corners of the wall and other areas that are difficult for the robot to work in.

Introduction of Painting Robot in Lacquer Ware
Painting of lacquerware, which used to be done by hand because of the need for skilled techniques, is now performed by a vertically articulated Painting Robot. The work, which previously required two people, can now be done by a single assistant, greatly increasing labor productivity by about threefold.

In addition, the new system contributes to solving the problem of technical succession due to the declining birthrate and aging population.

Introduction of Painting Robot for Roof Painting
In the case of the introduction of Painting Robot to the roof painting operation, labor productivity increased 35 times before and after the introduction of Painting Robot.

2. Painting Robot Painting Method

Painting Robots use an electrostatic coating method with a beautiful finish. Electrostatic coating is a coating method that utilizes the mechanism of static electricity. The workpiece is the positive electrode and the Painting Robot is the negative electrode. High voltage is applied to the atomized paint to charge the negative electrode, and the paint is applied to the positive electrode workpiece along the electrostatic lines. The advantages of this method are that less paint is wasted, the number of coating man-hours is greatly reduced. It is also environmentally friendly.

The most commonly used coating guns are the rotary atomization method and the electrostatic atomization method. The rotary atomization method spreads the paint in an application pattern while atomizing the paint. An air motor is rotated at high speed, compressed air is used to create an air film between the shaft and bearings. This mechanism rotates at high speed without contact. These rotations cause the paint to form a fine atomization, which is then pneumatically ejected in the direction of the workpiece.

The electrostatic atomization method uses electrostatic force to atomize the paint. The electrostatic coating method is widely used for mass-produced industrial products such as automobile bodies, railroad cars, electrical products, steel office equipment, and housing-related parts.

What Is a Pillow Packaging Machine?

Pillow packaging machines are used to package food, pharmaceuticals, machine parts, and other products.

It is called “pillow packaging” because the packaging form is shaped like a “pillow,” and it is suitable for high-speed mass packaging.

It can be filled with gas when packaging products, which slows down the speed of product deterioration.

Pillow packaging is not vacuumed sealable or aseptic and is unsuitable for heat-sensitive products because heat is applied during sealing.

Other types of packaging machines, such as shrink seal (heat shrink) packaging machines, small box packaging machines, and vacuum packaging machines, can also be used, depending on the product to be packaged.

Applications of Pillow Packaging Machines

Pillow wrapping machines are mainly used in the food industry and for bulk packaging of pharmaceuticals.

There are also packaging machines suitable for packaging pharmaceuticals, and each zone of machine is divided into separate zones.

Vertical pillow wrapping machines are not suitable for products that may be damaged if the product is dropped into the film from the top.

It is suitable for packaging flour, drinking water, mayonnaise, snacks, bean sprouts, machine parts, etc.

It can also be used for confectioneries individually packaged in a continuous vertical line and with gussets on the sides and bottom.

Horizontal pillow wrapping machines can pack tray containers, ice cream, chocolate, dried noodles, vegetables, toys, stationery, and pharmaceuticals in bulk but are not suitable for powders, granules, or liquids.

Horizontal pillow wrapping machines can be further classified into two types: “forward pillow wrapping machines,” in which the back seal is below the product, and “reverse pillow wrapping machines,” in which the seal is above the product.

Principle of Pillow Wrapping Machine

1. Vertical Pillow Wrapping Machine

The film is made into a tube, the overlapping parts are sealed, the product is filled from the top, and the top is sealed horizontally and separated.

Various functions can be added to the pillow wrapping machine, such as gas filling, gusset creation, film misalignment correction, product bite prevention, and sensor to prevent empty wrapping.

2. Horizontal Pillow Wrapping Machine: Positive Pillow Wrapping Machine

The film is fed from the top of the product and wrapped from the top to form a cylinder, and the overlapped portions are sealed. This machine is suitable for wrapping products on trays, products of a certain shape, and lightweight products. 3.

3. Horizontal Pillow Wrapping Machine: Reverse Pillow Wrapping Machine

The film is fed from the bottom of the machine, and the product is wrapped from the bottom to form a cylinder, and the overlapped portions are sealed.

Since the seal is on top of the product, it is easy to check for roll-in and is better suited for wrapping heavy products than regular pillow wrapping. Since the product is placed on top of the film, it is possible to wrap moist or long vegetables, and the conveyor is less contaminated.

Other Pillow Packaging Machine Information

The trouble with Pillow Packaging Machines

One trouble that can occur when working with a pillow-wrapping machine is film snaking. The cause may be a problem with the film or with the wrapping machine, and countermeasures must be taken according to the cause each time.

Typical causes and countermeasures for film snaking are as follows:

• If the Film is Too Thick or Too Thin: Installing a guide on the roller part of the wrapping machine or strengthening the brake on the take-up may improve the problem. Replacing the take-up is another solution.
• If the Film is Too Slippery: Installing guides on the packaging machine or wrapping the rollers with non-slip tape may be a solution.
• If the Film is Too Slippery: Powder dusting can be effective.
• Uneven Printing: Adjusting the roll stiffness may help.
• If the Installation or Rotation of the Wrapping Machine Rollers is Distorted: The rollers of the wrapping machine need to be adjusted.

Pillow wrapping machine film

In a pillow-wrapping machine, a sheet of film is sealed back-to-back and wrapped into a tube. To avoid seal failure, the appropriate sealing temperature must be selected based on the characteristics of each film material. There are various types of films used for packaging.

Typical film materials and characteristics are as follows:

1. Low-density Polyethylene (LDPE)

LDPE has excellent water resistance, acid/alkali resistance, heat sealability, and impact resistance. On the other hand, it tends to be inferior in organic solvent resistance and heat resistance. 

2. Non-oriented Polypropylene (CPP)

Compared to LDPE, CPP has superior moisture resistance and transparency. On the other hand, it tends to be inferior to LDPE in flexibility and impact resistance. 

3. Biaxially Oriented Polypropylene (OPP)

This is a film processed by stretching CPP film; it is less stretchable than CPP and has superior tensile strength, moisture resistance, and transparency. On the other hand, OPP-based films have a narrower temperature range and tend to shrink more easily. 

4. Polyvinylidene Chloride-coated OPP (KOP)

This film is an OPP film coated with polyvinylidene chloride. It has excellent moisture-proofing, gas-blocking, and aroma-retaining properties. 

5. Polyester (PET)

This film is made by biaxially stretching PET resin to provide strength and heat resistance. It is inferior in gas barrier properties, moisture retention, and impact resistance but is strong, has excellent heat/cold resistance, and has aroma retention properties.

What Is Used Wastewater Treatment Equipment

Used wastewater treatment equipment purifies effluent discharged from industry, agriculture, and other industries, as well as from sewage and other human waste.

Water treatment is an indispensable process in our daily lives in terms of efficient use of water, prevention of environmental pollution, and prevention of odors and other pollution. For this reason, many companies are striving for technological innovation to improve the efficiency of wastewater treatment.

Depending on the type of wastewater, removal of various types of substances is required, including heavy metal removal, organic matter removal, denitrification, and phosphorus removal.

Uses of Used Wastewater Treatment Equipment

Wastewater treatment equipment is used in all industries, including industry, agriculture, livestock, and water treatment plants.

In the industrial field, there is a strong demand for industrial wastewater recycling in Singapore, where water is scarce. Emerging countries such as China, the Middle East, and Southeast Asia require not only wastewater recycling but also sewage purification from the standpoint of environmental pollution prevention.

In the livestock industry, wastewater containing large amounts of livestock feces and urine is discharged in large quantities, so Used Wastewater Treatment Equipment is used to prevent environmental pollution and foul odors.

Principle of Used Wastewater Treatment Equipment

Used wastewater treatment equipment generally performs pretreatment, coagulation/precipitation separation, and filtration of the received sewage, and after adjusting the pH, etc., it is discharged or reused. The wastewater treatment process is divided into two major processes: pretreatment and biological treatment.

1. Pretreatment Process

In the pretreatment process, substances that inhibit biological treatment are removed. Heavy metals (copper, nickel, zinc, etc.) and suspended solids are treated by coagulation and sedimentation.

2. Biological Treatment Process

In the biological treatment process, organic matter is removed from the pretreated water using the decomposition ability of microorganisms. The amount of organic matter in the water is expressed in terms of BOD (biochemical oxygen demand) and COD (chemical oxygen demand), and the water is purified until these values fall below standards.

The activated sludge method is most commonly used in wastewater treatment and water purification plants. The activated sludge method refers to a method in which wastewater is treated by aerobic microorganisms using the dissolved oxygen in the water to break down organic matter through aeration and sedimentation and separation.

Another method is the biological membrane method. In the biological membrane method, microorganisms are attached to carriers to create a membrane-like structure that absorbs and decomposes pollutants in wastewater.

Other Information on Used Wastewater Treatment Equipment

1. Small Used Wastewater Treatment Equipment

Small wastewater treatment equipment is used at construction sites and small factories. This is because the amount of wastewater discharged is small and can be handled on an in-house scale.

Applications include wastewater from detergents, wastewater from grinding, and wastewater from food processing. Because of their small size, they can be transported by 2- to 4-ton trucks and can be easily installed. In addition, the system can perform the series of treatment operations described above, is simple to operate, and requires a low investment cost.

On the other hand, a large amount of domestic and industrial wastewater is discharged every day. Therefore, used wastewater treatment equipment itself is not suitable for use with small wastewater treatment equipment because of its large scale.

2. Used Wastewater Treatment Equipment in Factories

Factory wastewater contains many contaminants. Therefore, treatment equipment should be considered according to the type of pollutant and the wastewater characteristics of each factory.

Types of pollutants
Treatment facilities are considered for each substance, such as oil, organic matter, ammonia, and toxic metals in the treated wastewater. For example, activated sludge facilities are needed to reduce BOD (biochemical oxygen demand) and COD (chemical oxygen demand), while coagulation sedimentation facilities are needed to treat SS (suspended solids).

Wastewater Characteristics of Each Plant
The specifications of equipment differ for each plant because the concentration of hazardous substances in treated water, pH, and other wastewater characteristics are different for each plant, such as food, electronic parts, and petroleum/petrochemical plants. For food factories, these include anaerobic treatment using methane fermentation and filtration using bio-filters.

In the case of electronic component factories, inorganic wastewater and organic wastewater are treated separately because inorganic substances such as fluorine and arsenic are used in large quantities. In addition, the concentration of each toxic substance in the treated water at the plant is determined by the relevant laws and regulations. In order to achieve the required treatment concentration, the specifications of the equipment are determined after the preconditions for the amount of treated water and raw water concentration are established.

What Is an Ultrapure Water System?

An ultrapure water system is a device that produces ultrapure water. Natural water and tap water contain various salts and organic matter and are not ultrapure. In research and development, these impurities are likely to affect the results of experiments. In the manufacturing industry, impurities in water can affect product quality. Therefore, in these fields, ultrapure water from which impurities have been removed is used.

Among pure water, ultrapure water is the one with the highest degree of purity. Water purity is measured based on electrical resistivity. Theoretical purity of water is 18.24 MΩ-cm. In common parlance, ultrapure water is water that has achieved 18 MΩ-cm.

Uses of Ultrapure Water Systems

Ultrapure water is used in the research and development field and in semiconductor manufacturing. In the research and development field, it is often used in biotechnology experiments and clinical trials of pharmaceuticals. In the semiconductor manufacturing industry, it is used for cleaning semiconductor parts and precision equipment.

However, ultrapure water cannot be stored in glass containers or polyethylene tanks. This is because its dissolving capacity is much higher than that of tap water and dissolves containers in minute quantities. Therefore, ultrapure water is produced by an Ultrapure Water System and used only when necessary and in necessary quantities.

Principle of Ultrapure Water Systems

Ultrapure water systems purify tap water to produce ultrapure water. In this section, the principle is explained using a reverse osmosis membrane + ion exchange pure water device as an example. This system uses the three steps of filtration, reverse osmosis, and ion exchange to produce an ultrapure water system.

1. Filtration

Powdered activated carbon filters filter out impurities such as residual chlorine and large debris in the tap water.

2. Reverse Osmosis

Filtered tap water is purified by reverse osmosis. Normally, when aqueous solutions of different concentrations are separated by a semipermeable membrane, water molecules move from the solution of lower concentration to the solution of higher concentration. This is called osmosis.

As water molecules move, a force called osmotic pressure is generated, which eventually reaches equilibrium with the gravitational force on the volume of water moved. In contrast, when a pressure higher than the osmotic pressure is applied, water molecules can be moved from an aqueous solution of higher concentration to aqueous solution of lower concentration. This phenomenon is called reverse osmosis.

In an ultrapure water system, high pressure is applied to tap water to transfer water molecules that do not contain impurities to produce pure water. An osmosis membrane that can purify water molecules by this reverse osmosis phenomenon is called a reverse osmosis membrane. The water purified here is already pure enough to be called pure water.

3. Ion Exchange

The aforementioned inorganic ions contained in trace amounts in pure water are removed by ion exchange. Ion exchange is a method of improving purity through the use of ion exchange resins. Pure water produced by reverse osmosis contains trace amounts of calcium and chlorine ions. By filtering this pure water through an ion exchange resin, the impurity ions are adsorbed by the resin and become ultrapure water.

This is the main principle of the ultrapure water system. Ultrapure water systems are also available that include a UV sterilization system after the ion exchange is completed. There are also various types of products that reuse ion exchange membranes or distill tap water.

Other Information on Ultrapure Water Systems

1. Industrial Applications of Ultrapure Water Systems

An ultrapure water system is used in the cleaning process of semiconductor devices, as mentioned above. If the cleaning water contains microscopic impurities, there is a risk of short-circuiting the circuit. Therefore, the ultrapure water system is an essential part of semiconductor manufacturing technology.

Other uses include water for steam generators in steam turbine generators and water for humidification in factories.

2. Precautions When Using Ultrapure Water Systems

The ultrapure water system is a delicate device, and there are several precautions that must be taken in order to obtain high-purity ultrapure water. As a general rule, water should be collected on an as-needed basis, and the initial flow of water should be drained. This is because there is a risk of contamination of the area around the water sampling port by outside air. To prevent contamination from the environment, it is also necessary to keep the water sampling port clean and to avoid bubbling when sampling.

Ultrapure water is also known as hungry water. The name is derived from its ability to take in substances. Because of this property, its electrical resistivity decreases over time. Therefore, ultrapure water should be used as soon as possible after collection.

What Is a Gun Drill?

A gun drill is a specialized tool designed for deep hole drilling, originally developed for manufacturing gun barrels. It operates by ejecting high-pressure cutting oil through its tip, removing chips during the drilling process, and allowing for the drilling of deep or narrow holes in a single operation. With its excellent linearity, a gun drill is capable of creating precise holes in hard-to-machine materials such as stainless steel and heat-resistant alloys.

Uses of Gun Drills

Gun drills are ideal for drilling holes with depths over five times their diameter, particularly for diameters ranging from 3 to 30 mm. Their ability to eject chips during drilling makes them highly efficient and accurate for deep-hole drilling. Common applications include:

• Food Machinery: Parts for liquid filling machines, coolers, dairy milking machines, and other food processing equipment.
• Transportation Equipment: Components for automobiles, railroad cars, and aircraft.
• Industrial Machinery: Spindles, shafts, cylinders, injectors, hydraulic systems, and gear reducers.
• Electricity: Parts for electrical and electronic devices, semiconductor heat plates, and LCD manufacturing equipment.

Principle of Gun Drills

Gun drills utilize a high-pressure pump to inject cutting oil into the cutting area. The drill’s hollow design facilitates the circulation of cutting fluid, which carries chips out through a V-shaped groove in the drill’s shank. Different drill tip designs, such as kidney or two-hole types, offer variations in oil delivery and head rigidity. The long shanks of gun drills often require a drill bush at the machining point to enhance bending rigidity, ensuring minimal misalignment and high precision in drilling.

Other Information on Gun Drills

1. Gun Drilling Machines

Gun drilling is performed on dedicated machines, which are specialized lathes designed for this process. Unlike traditional lathes, the material is stationary while the gun drill rotates. Continuous injection of cutting oil from the drill’s tip prevents hole blockage and damage to the drill. Gun drills have a driver at their base, allowing them to be held by the machine’s chuck, with cutting fluid supplied through the drill’s shank.

2. Gun Drilling on Machining Centers

While dedicated gun drilling machines are ideal, gun drilling can also be performed on general-purpose machining centers, NC milling machines, and NC lathes for hole depths up to approximately 40 times the hole diameter. These machines must have a center-through coolant function. Due to the gun drill’s cutting-edge design, a pilot hole is typically required to initiate the drilling process to precise specifications.

What Is a Robotic Screwdriver?

A Robotic Screwdriver is a robot that automatically performs screw fastening tasks that were previously performed by a worker.

Robotic Screwdrivers automate screw fastening operations and increase manufacturing efficiency. In addition, the robot’s error detection function detects missing products caused by dropped screws or floating screws due to faulty screw work, enabling stable production.

There are many different types of screw fastening robot systems, including multi-axis robots, SCARA robots, parallel link robots, Cartesian coordinate-type screw fastening robots, dual-arm screw fastening robots, and small table-top types.

Applications of Robotic Screwdrivers

Robotic Screwdrivers are often used in production lines for mass-produced products. Robotic Screwdrivers are used for fastening screws in areas where human labor is inefficient. For example, the robot is useful for fastening machine cases, where many screws are used, or where the screw size is too small to be fastened by hand.

The robot can handle many types of screws, such as pot screws, countersunk screws, truss screws, Semmes screws, and Y recesses. It can also be adapted to hex bolts and hex nuts. A wide range of screw materials are available, including steel materials, aluminum alloys, and resin.

However, there are some areas where it is difficult to utilize Robotic Screwdriver. For example, when there is an obstacle nearby, on an inside surface, or when used in a deep hole. Therefore, it is important to select a model according to the application.

Principle of Robotic Screwdriver

A Robotic Screwdriver mainly consists of a robot, an electric screwdriver, a controller, and a screw feeder.

1. Robot

The robot is a device used to precisely position the electric screwdriver to the part to be fastened. There are various types of robots used for Robotic Screwdriver. SCARA Robots with multi-joints for easy movement and Cartesian Robots are often used.

2. Electric Screwdriver

This is attached to the end of the arm of the robot.

3. Controller

The robot’s position information and the electric screwdriver’s torque, rotation angle, and other information are controlled by the controller. The screw feeder stores screws and supplies them to the Robotic Screwdriver for efficient fastening work.

Other Information on the Robotic Screwdriver

1. Functions of the Robotic Screwdriver

The Robotic Screwdriver has a variety of additional functions to perform the screw fastening operation automatically. First, the controller connected to the electric screwdriver has functions such as torque and rotation angle management, torque and rotation angle control, screw fastening patterns, and good/fail judgment.

The tightening torque and rotation angle are very important information for automating screw fastening operations. Some models are also equipped with sensors to detect abnormalities or defects in the screw parts themselves, such as a screw hole being crushed or jammed. 

2. Coefficient of Friction Important for Screw Fastening

The key to proper screw fastening is to obtain the required axial force. Axial force is the force that holds the screw in place and is generated by the elastic force of the screw as it is pulled back. In normal screw fastening operations, it is not possible to directly check how much axial force was generated for each screw. Therefore, as substitute characteristics, the tightening torque and rotation angle are monitored.

The most common and widely used parameter is the tightening torque. Tightening torque is sometimes specified in assembly drawings of DIY products for the general public. However, proper axial force can only be obtained by tightening a screw with the specified tightening torque if the frictional force generated when fastening the screw is within the expected range.

Specifically, it is the coefficient of friction between the contact surfaces of the screw’s peaks and troughs, and between the head of the screw and the surface on which the screw is seated. If the coefficients of friction in the two areas related to the screw are higher than the expected range, sufficient axial force cannot be obtained even when working with the appropriate tightening torque.

Conversely, if the coefficient of friction is lower than expected, the axial force generated is too high and the screw may break or spin out. It is important to recognize that the tightening torque and rotation angle are only surrogate values for screw fastening, whether done manually or robotically, and that the correct axial force cannot be obtained if the coefficient of friction is not within the assumed range.

What Is Oil Mist Eliminator?

An Oil Mist Eliminator is a device designed to extract the lubricating oil used in metal processing by machine tools. This oil often becomes particulate due to high-speed operation. The device then condenses and discharges the graded oil into an oil outlet, subsequently releasing clean air into the external environment. In the field, it is commonly referred to as a “mist collector.”

Oil mist is harmful to the human body if it gets in the eyes or enters the respiratory tract. It can also create “haze” in the factory, causing poor visibility.

Uses of Oil Mist Eliminator

Oil Mist Eliminators are usually compact and mounted overhead on machine tools, while larger collectors are mounted horizontally on the machine.

The typical use of oil mist removers is to suck up the mist generated by the machine, remove the oil with a filter, and send clean air into the factory.

The filter naturally becomes dirty with oil, so periodic filter cleaning is required. In some cases, the filter itself is not needed, as some types of equipment use a filterless structure.

Principle of Oil Mist Eliminator

There are three main types of Oil Mist Eliminators: the filter method, which removes oil by sucking the aspirated mist through a filter, the electric method, which removes oil by using electrodes attached to the oil by electrostatic force, and the “centrifugal separation type,” in which a disc inside the collector is rotated at high speed and oil is separated by centrifugal force.

1. Filter-Type Oil Mist Eliminator

The filter type Oil Mist Eliminator is characterized by its simple structure, which makes it inexpensive to install. Due to its simple structure, it can be installed on top of the machine, thus taking up less space.

2. Electric Oil Mist Eliminator

Electric Oil Mist Eliminator, on the other hand, is complicated and expensive, but it is filterless and does not require filter replacement. Therefore, it does not generate industrial waste and is easy to maintain. However, because it uses high voltage, it must be handled with care.

3. Centrifugal Oil Mist Eliminator

Centrifugal Oil Mist Eliminator is inexpensive and easy to maintain because its structure is simple and filter-less, just like the filter type. The disadvantage is that it cannot capture particles smaller than 1 µm.