月: 2023年2月

What Is a Buffing Service?

A buffing service is a method used to smooth surfaces by eliminating irregularities. This process involves applying abrasives to a buffing wheel, typically made of cloth or similar materials, which then rotates to polish the object.

Suitable for both metal and plastic resin materials, buffing services enhance surface properties, providing chamfering, improved surface roughness, mirror finishes, and slipperiness. The buffing process, often performed before and after plating, allows for adjustable levels of finishing by varying the buffing materials and abrasives.

Uses of Buffing Services

Buffing services are essential for smoothing material surfaces, adding luster, removing burrs and chamfers, and enhancing surface finish post-plating. These services are particularly vital when specific surface roughness is required.

Typically, buffing employs materials like cloth, linen, wool, or sponge—softer than grinding wheels. Buffing grains are graded by numbers, such as “#00”; higher numbers indicate finer grains and a higher luster on the polished surface.

Principle of Buffing Services

Buffing works on the principle of micro-cutting action from abrasive grains. This action, combined with high-speed rotation-induced temperature rise (friction), produces a lustrous finish through both mechanical surface flow and the chemical impact of the abrasives.

The buffing process typically includes three stages: Rough Polishing, Intermediate Polishing, and Finishing Polishing.

1. Rough Polishing: Aimed at removing surface scratches, rough polishing is often the initial stage of buffing.
2. Intermediate Polishing: Following rough polishing, this stage enhances the material’s luster. Most buffed products are completed at this stage.
3. Finishing Polishing: This final stage is used for achieving semi-mirror or mirror finishes on the material’s surface.

The chosen process depends on the required finish quality; consultation with the processing manufacturer is recommended.

As outlined, buffing services significantly enhance product quality, contributing to improved durability and lifespan.

What Is Chrome Plating?

Chrome plating is a process where a metal surface is coated with chromium to enhance corrosion resistance, hardness, and aesthetics. This treatment, which covers the material with a chrome-based film, is notable for its silver color with a bluish hue, offering a distinct luster that enhances the item’s design. Despite its aesthetic appeal, chrome plating faces challenges in achieving uniform film thickness and electrical conductivity.

Uses of Chrome Plating

Chrome plating finds applications in both decorative and functional contexts. Decoratively, it is used on automotive exteriors, lighting fixtures, and accessories for its visual appeal and durability. For functional purposes, chrome plating is applied to parts requiring enhanced reliability and performance, such as in automotive and heavy machinery components, due to its exceptional hardness and resistance to harsh conditions.

Principle of Chrome Plating

The process involves submerging the material in a chromic acid and sulfuric acid solution, typically heated to around 122 °F (50 °C), and initiating an electrolytic reduction reaction. This reaction deposits chromium metal onto the material, forming a protective metal film. The distribution of this film can be uneven, with thicker deposits at high-current areas and thinner layers in low-current regions, posing a challenge in achieving consistent film thickness.

Types of Chrome Plating

Chrome plating is differentiated by the intended application.

1. Decorative Chrome Plating

Applied as a thin layer, often less than 1 μm, atop other metal coatings to impart a shiny appearance and improve corrosion resistance. It’s commonly used in automotive exteriors with multiple underlying metal layers for enhanced performance.

2. Hard Chrome Plating

Characterized by a thickness exceeding 1 μm, this industrial-grade plating emphasizes durability with a hard, wear-resistant film. Hard chrome plating is valued for its exceptional Vickers hardness and is applied in scenarios demanding high wear resistance.

Other Information on Chrome Plating

Types of Chrome Plating Baths

1. Hexavalent Chromium Main
Predominantly used in chrome plating solutions, hexavalent chromium is recognized as hazardous under international regulations. Despite its performance advantages, its use is controversial due to environmental concerns, necessitating careful waste treatment to mitigate its harmful effects.

2. Trivalent Chromium Main
As an environmentally friendlier alternative, trivalent chromium solutions have gained popularity. These solutions allow for a range of color tones and are often combined with bright nickel plating to preserve the metal’s luster.

What Is a Turret Punch Press?

Turret punch pressing is a metal fabrication process for punching holes and shapes into metal sheets. This process is akin to using a paper punch on paper but on a much larger scale and is conducted with a die. A turret punch press machine comprises an upper die and a lower die, with a turret that houses various shapes of dies for versatility. Through numerical control (NC) programming, it enables precise punching and forming of metal sheets into detailed and complex designs.

Uses of Turret Punch Presses

Turret punch pressing is versatile, allowing for the production of parts from thin metal sheets across various industries, including automotive, medical, and home appliances. It supports the creation of intricate designs without the need for specific dies, making it suitable for both high and low-volume production at reduced costs. This method is particularly prevalent in sheet metal fabrication for its efficiency and flexibility.

Principle of Turret Punch Presses

The principle of turret punch pressing involves laying a metal sheet on a die and systematically punching out parts as per the NC data, which dictates the punch and die’s movement. This process’s accuracy depends on the turret’s positioning and the metal plate’s characteristics, emphasizing the need for precise control to achieve the desired outcomes.

Types of Turret Punch Presses

Turret punching encompasses several processes tailored to specific fabrication needs.

1. Punching

A direct cutting process where multiple punches extract parts from a metal sheet.

2. Hole Punching

Similar to punching, but focuses on creating holes with the punched out material often considered scrap.

3. Slit Processing

Creates slits in a metal sheet, leaving the part still attached to the sheet.

4. Trimming Process

Removes excess material from parts shaped by other methods, refining the final product.

5. Half Cutting Process

Punches partially through the metal sheet without fully separating the part.

How to Choose Turret Punch Presses

Selection involves considering the sagging and shearing effects caused by the punching process, which impacts the metal sheet’s integrity and surface smoothness. It’s crucial to manage burrs, a common byproduct that may necessitate additional finishing processes. Turret punch presses are generally suited for metal sheets up to 0.118 inches (3 mm) thick, with laser processing preferred for thicker materials.

Other Information on Turret Punch Presses

Types of Turret-Punching Machines

Turret punching machines are categorized by their design and mechanism.

1. Turret
Features turrets for continuous multi-die processing.

2. Single
Lacks a turret, using only a single die for simpler tasks.

3. Mechanical
Employs a flywheel as the power source, known for its impact but also for generating vibration and noise.

4. Hydraulic
Utilizes a hydraulic pump, allowing adjustable processing speeds with reduced vibration and noise.

5. Servo Motor
Driven by a servo motor for precise control over the processing amount and speed.

What Is Extrusion Machining?

Extrusion machining is a forming technique where materials are pushed through a die to achieve a desired shape with consistent cross-sectional profiles. This process, applicable to metals, resins, and ceramics, allows for the production of complex and hollow shapes efficiently. Due to its capability to continuously produce molded products with uniform shapes and smooth surfaces, extrusion machining is crucial in various industries, including construction and manufacturing of household appliances.

Uses of Extrusion Machining

Extrusion machining’s versatility enables its application across diverse materials, producing items with uniform cross-sections. It’s extensively used for manufacturing building materials, industrial products, and components within familiar household appliances. Aluminum extrusions, for example, are fundamental in creating intricate shapes like sashes and heat sinks, while resin extrusions are pivotal for optical fiber production. This technology also extends to the food industry, shaping products like pasta and snack foods.

Principle of Extrusion Machining

Extrusion processes are categorized by processing temperatures—hot, cold, and warm extrusion—each affecting the extrudable shapes and the strength of the final product. Adjusting processing temperatures is essential for tailoring the product’s performance to specific applications.

1. Hot Extrusion

Performed above the material’s recrystallization temperature, hot extrusion allows for easy shaping due to the material’s low deformation resistance. This method is commonly used for metals like steel, requiring temperatures above 1,832 °F (1,000 °C).

2. Cold Extrusion

Conducted below the recrystallization temperature, cold extrusion is favored for parts requiring precision and smooth finishes, like automotive components, due to minimal thermal shrinkage and excellent dimensional accuracy.

3. Warm Extrusion

Operating at temperatures between hot and cold extrusion, warm extrusion combines the benefits of both, optimizing processing efficiency and product quality.

Types of Extrusion Machining

Diverse extrusion methods, including direct, indirect, and specialized techniques, cater to different material and design requirements:

1. Direct Extrusion

Also known as forward extrusion, this method involves pushing a heated billet through a die with a ram, requiring a robust container to manage friction-induced forming challenges.

2. Indirect Extrusion Process

In this backward extrusion approach, the billet is extruded through a die attached to the ram end, minimizing friction and enhancing stability during the process.

3. Conform Extrusion Process

This continuous extrusion technique is utilized for producing thin and long materials, with the die fixed at the wire rod’s destination, facilitating efficient material shaping.

4. Hollow Extrusion Process

Used for creating tubes or pipes, this method employs a mandrel within the die for drilling, with glass lubrication preventing temperature rise under high pressure.

5. Hydrostatic Extrusion Process

A liquid-pressurized billet is formed according to the die’s profile, suitable for long or composite materials, benefiting from reduced friction and temperature control advantages.

What Is Metal Stamping?

Metal stamping is a manufacturing process that involves using dies and press machines to apply significant pressure to a workpiece, shaping it into a desired form. This technique, a cornerstone of metalworking and plasticity processing, is crucial for producing components found in automobiles, home appliances, and a myriad of other familiar products. Despite the high initial investment in press machines and dies, metal stamping offers remarkable productivity and cost efficiency by enabling the mass production of identical shapes.

Uses of Metal Stamping

Metal stamping’s versatility supports a wide array of applications, making it integral to the automotive industry, where approximately 80% of stamped products are utilized. Beyond vehicles, this process contributes to the creation of large appliances, electronic devices, and everyday items. Its precision has also made it invaluable in fields requiring meticulous detail, such as semiconductor manufacturing, medical devices, and aerospace technology.

Principle of Metal Stamping

By placing a metal sheet between specially designed dies, metal stamping machines can deform the material into the specified part. The durability of the press machine and die ensures the continued production of parts at minimal costs. Dies used in stamping are categorized into single-shot, progressive, and transfer molds, each suited to different production scales and complexities.

Types of Metal Stamping

The method chosen for metal stamping depends on the desired outcome, with primary techniques including shearing, bending, and drawing:

1. Shearing

A method for cutting steel sheets into specific sizes or shapes, shearing is also used for punching out sections from a material, akin to hole punching or die-cutting.

2. Bending

This process bends materials into shapes such as V, U, or L, allowing for the creation of complex forms used in various applications, notably in automotive bodies.

3. Drawing

Drawing stretches a material into a container shape by applying pressure between a punch and die, a common technique for creating hollow, rounded components.

How to Select Metal Stamping Processes

Choosing the right metal stamping process involves considering the balance between the high precision and low unit cost achievable through mass production against the substantial initial investment in press machines and dies. Proper maintenance and storage of dies are crucial to prevent damage and maintain cost-effectiveness over time.

What Is Thread Rolling?

Thread rolling is a plastic-forming process where a strong force is applied to a workpiece, causing deformation. The thread-rolling dies press against the rotating workpiece.

Metals suitable for thread rolling include iron, aluminum, brass, and stainless steel. Materials should have an elongation of 5% or more and a tensile strength of up to 1700 N/mm².

Plastic forming, including thread rolling, is widely used in industrial production. It generally requires less processing time than other methods, resulting in reduced material waste and lower energy consumption. Other forms of plastic forming include extrusion, rolling, pressing, and forging.

Uses of Thread Rolling

Thread rolling, initially developed for producing male threads, creates thread-rolling screws. These screws are stronger than those formed by cutting metal. The process’s high efficiency makes it ideal for mass production.

Various threads can be produced by altering the thread rolling dies. These include metric, trapezoidal, tapered, and specially formed screws.

Besides screw production, the thread-rolling process is also employed in machining parts like gears and worms.

Types of Thread Rolling

The primary methods of thread rolling are flat die, round die, and planetary thread rolling. Each method is outlined below:

• Flat Die Thread Rolling:
  This method involves sandwiching the workpiece between two flat dies, with one fixed and the other moving. It’s highly productive and commonly used for mass-producing general-purpose screws.
• Round Die Thread Rolling:
  This method uses cylindrical round dies to sandwich the workpiece, rotating in the same direction and speed. It’s versatile and used for metalworking beyond screw production due to adjustable die spacing.
• Planetary Thread Rolling:
  This method uses an outer arched segment die and an inner round die, with only the round die rotating. It’s highly productive and suitable for high-volume production of general screws.

What Is 5-Axis Machining?

5-axis machining is a machining process that combines X, Y, and Z axes with rotary and tilting axes. In conventional 3-axis machines, the change of machined surfaces is done manually; by adding 2 axes to NC machine tools, the change of machined surfaces can be automatically controlled, resulting in shorter machining times and improved accuracy.

A 5-axis machining machine is available in two types: table type and tool type. The table type has two additional axes on the table where the material to be machined is set. The tool type, on the other hand, has two additional tool axes on the machine side. In addition, there is a type with one axis added to the table and one axis added to the tool.

Uses of 5-Axis Machining

5-axis machining is used for machining parts with complex shapes, such as continuous three-dimensional curved surfaces and undercuts (parts where the machined part is hidden from view), which are difficult to achieve with 3-axis machining.

Impellers, blisks (integrated rotor blades), and turbine blades manufactured by 5-axis machining are used in aircraft, centrifugal pumps for liquids and gases, generators, and other applications. In addition, they are used to machine products and parts in a wide range of fields, including precision machinery, molds, medical devices, artificial joints, and dentures.

Types of 5-Axis Machining

There are two types of 5-axis machining: indexing 5-axis machining and simultaneous 5-axis machining. The characteristics of each are as follows:

• Indexable 5-Axis Machining
  Indexable 5-axis machining is a method in which the machined surface is indexed by 2 axes added to the table side and machined by 3 axes on the machine side. This method is used for table-type 5-axis machining machines. Since the size and weight of the material to be machined depend on the size of the table, a 5-axis machining center of the appropriate size for the material to be machined is required. In addition, undercutting requires multiple adjustments to the machined surface. On the other hand, it is easier to adjust misalignment on each axis than with a simultaneous 5-axis machining machine.
• Tool Types of 5-Axis Machining
  This machining method is used with a tool-type 5-axis machine that has two additional axes on the tool. Although the additional tooling increases the size of the machine, it allows for greater machining flexibility and a wider machining range. It is also possible to machine 3-dimensional curved surfaces, which is not possible with indexable 5-axis machining. In addition, 5-axis machining is performed simultaneously for undercutting, eliminating the need for workpiece angle adjustment.

What Is a Polishing Service?

Polishing is a finishing process that improves a workpiece’s surface by using abrasives to enhance its precision, quality, appearance, and texture. It’s a critical step in the manufacturing of a wide range of products, from metals to jewelry and electronic components, offering benefits like corrosion resistance and improved aesthetic appeal.

This method employs various abrasive materials, allowing for the meticulous removal of surface irregularities. The resulting polished metal can achieve a mirror-like finish, often referred to as a mirror finish.

Uses of Polishing Services

Polishing services cater to a broad spectrum of applications, ensuring products meet precise specifications. It’s integral in the production of optical components, where a reflective surface is essential, and in enhancing the visual and tactile quality of items such as jewelry. Polishing also plays a vital role in maintaining the functionality and longevity of products by preventing rust and dirt accumulation.

Principle of Polishing Services

The polishing process involves several stages to achieve the desired finish.

1. Basecoat

Initial removal of major surface irregularities using a coarse grindstone, setting the stage for finer work.

2. Smoothing

A finer grit is applied to eliminate remaining imperfections, preparing the surface for further refinement.

3. Polishing

The surface is brought to a shine with even finer abrasives, essential for achieving a high-quality finish.

4. Mirror Finish

The ultimate goal, producing a surface with a reflective mirror-like quality through careful application of abrasives.

Types of Polishing Services

Several polishing methods are available, each suited to different materials and desired outcomes:

1. Grinding Wheel

A method where a rotating grinding wheel polishes the workpiece surface, effective for continuous operation due to the self-renewing abrasive grains.

2. Buffing

Uses a soft material like felt along with fine abrasive grains to achieve a high luster, often employed for final touches.

3. Electropolishing

An abrasive-free technique that smoothens surfaces by chemical dissolution in an electrolytic solution, suitable for delicate applications in the medical and food industries.

4. Lapping and Polishing

A method where abrasive grains are applied between the workpiece and a lapping table, achieving a high degree of smoothness suitable for finishing tasks.

5. Abrasive Cloth/Paper Processing

Similar to sanding, this process uses abrasive cloth or paper to polish the workpiece, adaptable to various shapes and sizes.

6. Barrel Finishing

A bulk processing method where workpieces are polished in a machine filled with abrasives and water, ideal for deburring and surface smoothing.

 

 

What Is Steel Processing?

Steel processing refers to all activities performed on steel and encompasses fundamental metal processing.

Steel is a type of metal that falls between “pure iron,” almost 100% pure, and “cast iron,” which has a carbon content of 2.14% or higher.

Further categorizations of steel include “ordinary steel (carbon steel),” containing silicon, manganese, phosphorus, and sulfur other than carbon, and “special steel,” which also contains nonferrous metals (chromium, nickel, molybdenum, etc.).

As a crucial material supporting the industry, steel has undergone continuous improvement, leading to various types of steel processing for different purposes.

Uses of Steel Processing

Steel processing serves as the foundation of metal processing in various ways, with ongoing material optimizations during the processing stage.

Hence, in steel processing, the selection of the most suitable material for processing becomes a critical point.

Currently, ordinary steel products include SS (general structural rolled steel), SR (welded structural rolled steel), and SPC (cold-rolled steel sheet and strip).

Specialty steels include alloy steels (SC, SCr, and SCM materials), tool steels (SK, SKH, SKS, and SKD materials), and special-purpose steels (spring steels, bearing steels, and stainless steels).

The abbreviations used adhere to JIS designations, with the first letter of the alphabet indicating the initial letter of Steel. The next letter indicates the standard or product name: S for Structure, P for Plate, K for Tool, C for Casting, and R for Rolled.

Types of Steel Processing

For small workpieces, “machining” with a fixed workpiece and “turning” with a rotating workpiece are typical types of steel processing.

For large workpieces, steel processing primarily involves welding, sheet-metal working, and press working using large machines.

Classified by processing method, cutting, bending, welding, and cutting are commonly performed, as in various types of metal processing.

In addition, steel processing includes various newly developed processing methods using new technologies.

In the cutting process, besides cutting with a press, “laser processing” with a laser beam is used. In the bending process, three-dimensional bending with the use of a computer is applied.

In welding, the use of laser welding technology, which utilizes laser beams and produces minimal sparks, is steadily increasing.

Similarly, in the cutting process, the revolutionary “metal 3D printer” has moved beyond the development stage and is steadily advancing to the practical stage.