月: 2023年2月

What Is a Wire Processing Service?

A wire processing service is a process in which an electric current is applied to a very thin wire to heat and melt the metal to be processed. It is most commonly referred to as wire processing service. It does not produce burrs, which occur in press work, and can perform high-precision processing to the nearest 0.01 mm.

The advantage of this process is that it can be applied to all types of metals, and the shape of the material to be processed does not matter. On the other hand, there are some disadvantages, such as the processing time required and the inability to process materials that are not conductive.

Uses of Wire Processing Services

Wire processing services can be performed at high temperatures of nearly 7,000°C, making it possible to process materials that are difficult to process, such as heat-resistant alloys and high-hardness metals. It can also be used to process parts with complex shapes because it can process any size or shape of the material to be processed.

Wire processing services uses ultra-thin wire and can process without touching the work material, thus enabling burr-free, high-precision processing without placing a burden on the work material.

With these advantages, wire processing services are used to process all kinds of metal parts, including plate and ring parts, pipes, and metal fittings.

Because it is not suitable for mass production, it is often used for custom-made, high-precision processing of special parts.

Principle of Wire Processing Services

Wire processing services melts the metal to be processed by the heat of a metal wire that has an electric current flowing through it. The wire is often made of highly conductive brass and is very thin, with a radius of 0.05 mm to 0.3 mm.

The wire does not directly touch the material to be processed, and the distance between the material and the wire is kept at a very short distance of several tens of micrometers. Therefore, wire processing services can be performed with a width of about 0.4 mm with high precision.

The wire is heated to nearly 7,000°C. This is much higher than the melting point of about 4,000°C, which is the melting point of the metal with the highest melting point on earth, so it can be said that wire processing services can be applied to all kinds of metals.

Wire processing services are performed in water tank filled with pure water. This is to prevent expansion and deformation of the material to be processed due to heat. The water tank is equipped with a cooling system to maintain a constant water temperature.

In addition to the method in which the workpiece is completely submerged in the tank, there is also a jet-type wire processing services in which pure water is sprayed on the workpiece.

What Is a Shearing Service?

Shearing is a metal cutting process utilizing shear force. As a subset of stamping, it shapes or divides metal into parts through operations such as blanking and piercing. Unique among metalworking methods, shearing exclusively focuses on cutting without removing material.

Shearing employs a die to exert shear force on metal, precisely cutting it into the required shape. This process capitalizes on the force between the press and the metal, essential for achieving the desired configuration.

Uses of Shearing Services

Shearing plays a foundational role in metalworking, shaping components like automobile frames through press-applied shear force. It initiates the sheet metal forming process through blanking, setting the stage for further shaping in the production of furniture, building materials, and machinery parts.

Moreover, shearing facilitates the creation of metal enclosures by punching out curved lines in sheet metal, using either pre-existing dies or employing nibbling for more complex shapes.

Principle of Shearing Services

The principle behind shearing involves clamping metal between an upper punch and a lower die to generate shear force, effectively splitting the metal. This process may result in burrs or distortions, underscoring the challenge of producing precise parts without subsequent finishing steps.

Shearing outcomes can include parts with directional burrs, highlighting the importance of deburring for accuracy.

Types of Shearing Services

Shearing encompasses several techniques, with blanking, drilling, and compound processing as prominent examples.

1. Blanking

Blanking shapes metal sheets into pre-press forms, involving shearing, dividing, and punching based on the blank’s characteristics.

2. Drilling

Drilling involves creating holes in metal sheets, producing scrap from the punched areas. It can range from the multiplicity of holes for complex shapes to closely spaced holes achieved through nibbling.

3. Compound Processing

Also known as total punching, compound processing allows for simultaneous cutting and punching, enabling efficient mass production of precise parts, albeit with higher maintenance costs.

What Is Ironwork?

Ironwork is the processing of iron. Iron is abundant, constituting one-third of the Earth’s weight, making it cost-effective compared to other metals. It is also known for its high strength.

For centuries, iron has been widely used worldwide, and today, it accounts for 90% of metal products.

It is also frequently used in alloys such as stainless steel. Iron’s widespread usage is attributed to its ease of workability and versatility in processing.

Uses of Ironwork

Processing is an essential part of using ironwork for parts and products.

For instance, products are formed through casting, where molten material solidifies in a mold, or through cutting and machining using tools. Heat treatment, including quenching and tempering, can alter the metal’s crystal structure, increasing hardness and modifying properties.

Despite its utility, ironwork is prone to rust, so it is often coated after processing.

Types of Ironwork

There are many different types of ironwork, including:

• Cutting Processing
  This involves cutting iron using a shearing machine. It’s a crucial process affecting product accuracy and subsequent processing, requiring precise cutting with minimal burrs and warping.
• Bending
  This is the process of deforming a product to fit a die using a bender machine. The object to be bent is placed on the die and deformed by pressing it with a punch from above. Although simple, this process is prone to distortion and warping. It is an important process that has a significant impact on product quality.
• Welding
  Welding is the joining of metals by high heat and pressure. There are various types of welding, such as shielded arc welding, which uses a welding rod to generate an arc between base metal, spot welding, which uses heat generated by electrical resistance, and gas welding, which melts and hardens metal solder. Welding strength and precision are especially important for container-shaped products.
• Cutting
  Cutting is the process of shaving or drilling a hole in metal using a tool. There are two types of machining processes: milling, in which the object is fixed and the machine rotates, and turning, in which the object is rotated. In both cases, the compatibility of the machine and the object must be fully considered, including resistance, temperature, and speed.

 

What Is Laser Micromachining Service?

A laser micromachining service is a process of drilling holes or grooves in a workpiece by irradiating a laser beam intensively over a small area. Compared to processing using a die, laser microfabrication does not generate burrs and can produce smooth, high-precision processing. It is used especially for fine processing in minute areas.

There are various wavelengths of lasers used, each of which has its suitable application. Ultrashort pulsed lasers are most commonly used. In addition to drilling holes and grooves, there are various other processing methods such as marking and welding.

Uses of Laser Micromachining Services

Laser micromachining services can produce a smooth finish with minimal burrs and dross. In addition, since the processing can be focused on the area to be processed, there is little deformation due to heat. Laser micromachining services are characterized by their ability to perform precision processing without coming into contact with the material and to handle various materials.

Specifically, laser micromachining services are used in various processing methods, the most typical of which is the drilling of holes and grooves. These processes are used for drilling holes in circuit boards and films, manufacturing semiconductors, etc.

Types of Laser Micromachining Services

• Wavelength of Laser Used
  There are three types of laser micromachining services, depending on the wavelength of the laser used: near-ultraviolet laser, far ultraviolet laser, and ultrashort pulsed laser.

  Near-ultraviolet laser micromachining services use electromagnetic waves with wavelengths between 355 nm and 532 nm and are used for microfabrication, micro-hole processing, and thin-film surface processing.

  Far ultraviolet laser micromachining services are laser processes that use electromagnetic waves with short wavelengths between 157nm and 308nm and are used for micro drilling, large-area processing, and ring roughing.

  Ultra-short pulsed laser micromachining services are laser processes that use electromagnetic waves with a long wavelength of around 1000 nm and are used for internal processing of transparent objects, 3D optical waveguide processing, and high-performance non-thermal processing. They are called nanosecond lasers, picosecond lasers, femtosecond lasers, etc., depending on the wavelength of the electromagnetic waves used.

• Processing Method
  There are various processing methods using laser micromachining services. The following are some examples:

  Microplate processing is a laser micromachining service for acrylic, ABS, and other materials. It is widely used in the field of science research.

  Marking processing enables microfabrication without causing thermal damage to the material. In addition to resins and ceramics, it can also be used for materials that are difficult to process, such as copper and gold.

  Drilling can create burr-free precision holes of several tens of micrometers. It is also possible to drill fine holes intensively.

What Is a Ball Milling Service?

A ball milling service is a cutting method used in milling machines and NC (Numerical Control) machine tools. It employs a cutting tool with a rounded, ball-shaped endmill tip. This spherical tip is particularly suited for cutting complex 3D curved surfaces, including both convex and concave shapes. Ball milling excels in operations where other end milling techniques struggle, such as peripheral cutting on R surfaces and grooving. Unlike other methods, ball milling achieves higher precision and requires less labor when machining curved surfaces.

In addition to ball end mills, tools like square end mills, radius end mills, and other types of end mills, such as tapered end mills, are commonly used. Tapered end mills gradually narrow down towards the tip.

Uses of Ball Milling Services

Ball milling services are particularly effective for machining curved surfaces. They are frequently employed for copy milling and radius machining in NC machine tools. While primarily used for curved surfaces, ball milling can also handle flat surfaces, pockets, and various other forms. However, its spherical blade tip means it cannot perform machining without an R (radius).

Using 4-axis and 5-axis milling machines allows for cutting various shapes, making ball milling services ideal for manufacturing complex parts such as automobile and aircraft components, molds, etc. Additionally, preventing the zero peripheral velocity point at the tool tip extends blade life and increases work speed.

Principle of Ball Milling Services

Ball milling services are essential for cutting 3D curved surfaces, crucial in the creation of increasingly complex molds and parts. This method enables a high degree of precision in finishing curved surfaces, potentially reducing the time needed for final manual polishing.

The primary drawback of ball milling is the spherical blade tip, which leaves a cusp when cutting flat surfaces, leading to a less desirable surface finish. To improve this, machining paths are overlapped, which increases cutting time. Furthermore, the accuracy of the machined surface depends on the contact point between the ball mill and the material. By tilting the ball end mill for optimal cutting, one can achieve high precision and prevent tool breakage. However, adjusting the angle to match the material’s curved surface complicates the programming process.

Tilting the endmill is not feasible with a 3-axis machine; a 5-axis machine, however, can facilitate time-saving and enable high-precision cutting.

What Is a Stamping Die?

A stamping die is a tool used in the stamping process to shape products.

It comprises a pair of upper and lower dies designed to interlock. When combined, these dies form the desired shape. Set in a stamping press, the dies apply pressure to the metal being processed, causing plastic deformation and shaping the metal.

There are two main types of stamping dies: dies, which press flat metal sheets between upper and lower dies, and molds, used for casting and plastic molding, where molten material is poured into the die.

The type of press machine used can vary, with some being manually operated and others capable of automated, complex shape formation using multiple dies.

Stamping dies enable bending, shearing, and drawing – key processes in metal product fabrication. Specific dies like bending dies, shearing dies, and drawing dies are used for these respective processes.

Uses of Stamping Dies

Stamping dies are vital in manufacturing various products due to their ability to mass-produce identical shapes quickly. They are commonly used in making parts for automobiles, motorcycles, medical equipment, and construction materials, all requiring precision and efficiency in their production.

Different stamping dies are designed for various processes like shearing and bending.

The press machine’s pressure is crucial in stamping, where the die is pressed against the metal to induce plastic deformation. Note that while higher press performance facilitates easier forming, it also increases press forming efficiency and operational electricity costs.

Principle of Stamping Dies

Stamping dies are manufactured using machining centers, where the desired shape is cut and heat-treated. Die fabrication typically takes 3 to 6 months, depending on the product’s size and complexity.

Materials like alloy tool steel, known for its toughness, and high-speed tool steel, recognized for heat and wear resistance, are used for stamping dies due to the high pressure involved.

Stamping dies can be broadly categorized into two types based on their operation during stamping. However, it’s important to note that the definitions of these categories can vary.

1. Die

Dies are primarily used for processing metal sheets. In these dies, the metal is placed between the open upper and lower dies, and then the upper die is pressed into the lower one to form the shape.

2. Mold

Molds are mainly used for processing plastics. Molten resin is poured into the closed upper and lower molds, and then allowed to cool and harden before the formed product is removed.

Types of Stamping Dies

Stamping dies come in three main types:

1. Single-Shot Mold

A single-shot mold performs one type of stamping process continuously. It’s the most common among the three types and can handle one to several stamping processes. Its simplicity makes it cost-effective, though it is less efficient due to manual operation.

2. Progressive Die

A progressive die houses multiple stamping processes within a single die. It automatically transfers metal to the next process, enabling efficient, high-precision production. Though complex and costly to produce, it’s the fastest among the three types and accommodates complex shapes.

3. Transfer Die

A transfer die links single-shot dies for each process via a transfer mechanism. It combines the large processing capability of single-shot molds with the automation of progressive molds. While production costs are higher and processing time slower than progressive dies, it offers high versatility.

What Is a Wire Processing Service?

A wire processing service is a method where long, thin metal materials are formed into desired shapes using techniques like bending, cutting, welding, and forging. Forming machines and coiling machines are commonly used, with press machines for more complex shapes.

Uses of Wire Processing Services

Wire processing services are not just limited to bending. They can produce various products, including welded wire meshes and threaded wire tips. Typical products include wire, screws, wire mesh, springs, and wire rope. This service is essential in creating diverse items like car seat springs, clothes hangers, protective netting, and fryer baskets.

Principle of Wire Processing Services

Wire processing relies on the metal’s plasticity, primarily forming shapes through bending, combined with welding and crushing. Less cutting means reduced material waste, although this method is less precise than cutting.

1. Bending

NC forming machines enable complex bends and cuts, ideal for spring shapes and mass production without the need for dies. Coiling machines are also used for quick and simple spring shapes.

2. Welding Process

Spot welding is primarily used for joining materials, while butt welding joins wire rod ends.

3. Press Working

When NC machines are not suitable, benders, manual bending machines, or press machines are used, especially for small-lot production. Press machines enable mass production with fabricated dies.

Post-processing includes surface treatments like painting, plating, and vinyl or nylon coating to prevent oxidation.

What Is Aluminum Plating?

Aluminum plating involves bending, pressing, and cutting aluminum sheets into desired shapes. This material is favored for its affordability, lightweight, and excellent workability, including electrical and thermal conductivity. Despite its softness, alloying aluminum with metals like magnesium and copper enhances its strength, making it ideal for use in vehicles, sporting goods, and cooking utensils, as well as numerous everyday items.

Uses of Aluminum Plating

The versatility of aluminum sheet processing is evident in its application across various sectors, from household items to sports equipment and vehicles. Its accessibility and ease of processing facilitate a wide range of DIY projects, such as signs, dog tags, rings, and keychains. Aluminum’s lightweight nature makes it indispensable in aviation and space exploration, where minimizing weight is crucial. Additionally, aluminum alloy sheets offer improved corrosion resistance and strength, expanding their use to electrical appliances and construction materials.

Principles of Aluminum Plating

Aluminum sheet processing encompasses several techniques.

1. Bending

Bending aluminum sheets into vertical or curved shapes can be achieved through various methods, such as roll bending and sheet folding. This cost-effective process requires no dies, but must be carefully managed to avoid spring back.

2. Press Working

Press working involves shaping aluminum sheets with a die, facilitating the mass production of simple parts. While efficient for creating uniform products, the setup costs for press working can be high.

3. Cutting Process

Cutting aluminum sheets into specific shapes or sizes can be labor-intensive and less suited for mass production but allows for high precision in the final product.

Other Information on Aluminum Plating

Types of Aluminum Plates

Aluminum plates vary by alloy series, affecting their properties.

1. 1000 Series Aluminum Sheet
Comprising over 90% aluminum, the 1000 series offers high purity but low strength.

2. 2000 Series Aluminum Sheet
The 2000 series, or duralumin, is an aluminum, copper, and magnesium alloy, noted for its high strength but susceptibility to corrosion.

3. 5000 Series Aluminum Sheet
This series, an aluminum and magnesium alloy, is praised for its processability, strength, and corrosion resistance, making it highly versatile.

4. 6000 Series Aluminum Sheet
Composed of aluminum, magnesium, and silicon, the 6000 series is favored for its strength and corrosion resistance across various applications.

What Is Gold Plating?

Gold plating is the process of coating a material’s surface with a layer of gold. This technique enhances attributes such as corrosion resistance, electrical conductivity, and solder wettability, while also providing the aesthetic appeal of gold’s natural luster. Gold plating can involve the creation of alloy films with metals like cobalt, nickel, and silver, with nickel and copper commonly used as base layers for the substrate. Its applications are diverse, ranging from decorative purposes in the jewelry and automotive industries to critical roles in semiconductor manufacturing.

Uses of Gold Plating

Gold plating finds extensive decorative applications in jewelry, automotive emblems, Buddhist altar fittings, and watch parts, adding both durability and a sense of luxury. Industrially, it plays a vital role in enhancing the functionality of semiconductor parts and board joints by improving conductivity and solderability. Gold plating is crucial for preventing the oxidation of copper circuits, with recent advancements expanding its use to intricate wiring in high-performance boards. The method of hard gold plating, which increases film hardness, is particularly suited for components like electronic device terminals and connectors that frequently come into contact with external elements.

Principles of Gold Plating

Gold plating can be executed through electrolytic plating, where an electric current causes a reduction reaction that deposits metal ions as a film on the cathodic material. Alternatively, electroless plating relies on chemical reactions, either through substitution where underlying metal films are replaced by gold due to ionization tendencies, or autocatalytic processes where gold deposits continually as a catalyst. These methods vary in film thickness control, with electroless plating offering highly uniform thickness across non-conductive materials.

Other Information on Gold Plating

Gold plating processes vary from soft gold plating, which emphasizes purity and softness for semiconductor applications, to hard gold plating, which involves alloying with other metals for enhanced wear resistance and is primarily used in industrial settings. The industry continues to evolve, with research focusing on reducing the use of hazardous substances like cyanide in plating solutions and exploring electroless methods for achieving hard gold plating without compromising component integrity.

What Is Rebar Fabrication?

Rebar fabrication refers to the process used in reinforced concrete (RC) construction to strengthen concrete in building frames. Rebars are available in 12 different thicknesses (D10 to D51) and are made from rolled steel with surface ribs.

Uses of Rebar Fabrication

Reinforcing steel bars are used in buildings, with specifications varying by location. The construction process involves assembling steel bars in foundations, columns, beams, walls, and floors. Columns feature vertical and horizontal bars with hoop wrapping, while floors use main bars and reinforcement bars. Bar intersections are secured with wires.

Types of Rebar Fabrication

Rebar fabrication mainly uses deformed steel bars. It involves cutting bars to specific lengths and bends, using rebar cutters or automatic cutting machines. Bending is done with automatic machines or onsite using an electric tool with a rebar bender. The main bending shapes are “R bending” and “spiral bending.”

Rebar names vary by use, including under bars in foundations, column bars, beam bars, wall bars, and slab bars in floors.