月: 2023年3月

What Is a File Set?

A file set is a collection of files in various shapes and sizes, designed for shaping and smoothing materials. The most common file sets include 5-file, 8-file, and 12-file sets. The 5-file set, which includes typical shapes like cylindrical, flat, and triangular, suffices for most purposes. The 12-file set, with more variety, is often used by professionals in intricate work, such as jewelry engravers.

Uses of File Sets

Files are essential tools for working with materials like wood and metal, used for tasks like smoothing surfaces or removing paint. The variety of shapes in a file set allows for greater flexibility in matching the file to the specific part of the material being worked on. Additionally, files are also used for shaping plastics, making them versatile tools in wood and metalworking, as well as plastic modeling.

Principle of File Sets

Files are typically made from hard metals like carbon steel, with a textured surface known as the “blade.” This blade, when rubbed against a material, gradually shaves it off. The effectiveness of a file depends on the hardness of both the file and the material. The design of the file’s blade allows for sharpening by pressing the file against the material during use. Files vary in coarseness, serving different purposes from rough grinding to finishing. Diamond files, with diamond particles, and files specialized for ironworkers or woodworkers are available in sets, with options for coarser or finer grits to suit specific applications.

What Is an Eye Bolt?

An eye bolt, also known as a rod-end bolt, is a bolt with a circular or rectangular head that features a hole in the center. Synonyms for eye bolt include “swing bolt,” although “rod-end bolt” is the more commonly used term. Eye bolts, including suspension bolts, are typically used as fittings to attach machinery or other enclosures and are often lifted with a lobe or wire.

Uses of Eye Bolts

Eye bolts are utilized for securing manhole covers during maintenance in factories and power plants and in valves for tightening packing gland seals to prevent fluid leakage. They function similarly to hinges, securing parts that open and close on devices and machines. Since they can be integrated with the device or machine, they prevent the bolt from falling off and allow for easy operation.

Principle of Eye Bolts

Eye bolts are attached by inserting a pin or bolt into the ring hole in the bolt head, allowing the eye bolt to rotate or swing. A nut, wing nut, or knob is screwed onto the threaded portion of the bolt to secure the attached object. Eye bolts are designed to be integrated with the equipment, preventing them from falling off when detached from the threaded hole.

Types of Eye Bolts

Types of eye bolts can be classified as follows:

1. Head Shape

Figure 4. The head shape of the hinge bolt

Eye bolt head shapes can be circular, semi-circular, or rectangular.

2. Dimensions

Figure 5. Dimensions of hinge bolt

The dimensions of eye bolts are primarily expressed in terms of thread outside diameter (D), overall length (L), and thread length (S). The thread length is for a partially threaded part, not a fully threaded part. The hole diameter of the ring may be determined by the screw O.D. or may be pre-processed to the required hole diameter by the user with only a small diameter hole.

The screw’s outer diameter ranges from M6 to M30.

3. Types of Screws

The direction of the screw is right-hand thread or left-hand thread.

4. Material

Common materials for eye bolts include:

• Iron SS400, etc.
• Carbon steel S45C, etc.
• Alloy steel SNB7, etc.
• Stainless steel SUS304, SUS316, etc.
• Titanium steel, etc.

5. Surface Treatment

Surface treatments like uni chrome plating and trivalent chromate treatment are applied mainly to iron, carbon steel, and alloy steel eye bolts to prevent rust and corrosion.

What Is a Leveling Foot?

A leveling foot is a device attached to the bottom of structures like trestles to adjust their height. It consists of a conical pad touching the ground and a bolt oriented towards the apex. The bolt is inserted into a frame attached to the trestle, allowing height adjustment by securing the bolt at various positions. To prevent loosening, a nut is used to firmly secure the bolt to the frame.

Uses of Leveling Feet

Leveling feet are commonly used in industrial and academic settings, particularly on trestles and machine tools. They facilitate the installation of equipment on uneven surfaces by compensating for ground irregularities, thereby ensuring horizontal alignment. However, care must be taken during installation to avoid straining the frame.

Principle of Leveling Feet

The functionality of a leveling foot lies in its ability to adjust the height of a structure by tightening a bolt. The conical part at the bolt’s end makes ground contact, supporting the structure. Height adjustment is typically achieved by rotating the bolt in threaded holes on the frame, although methods using two nuts to secure the pad without threaded holes are also common.

Some leveling feet designs include rollers for easy movement of the equipment. The rollers are grounded when moving the equipment, and the pad is placed on the ground to secure the machine when stationary.

Types of Leveling Feet

Leveling feet come in various types, each designed for different loads:

1. Low Load Type

Used for lighter structures, these feature smaller bolts (around M5) and a thinner conical ground contact part. The ground surface area is often enlarged for increased stability.

2. Heavy Load Type

Designed for heavier loads, these have larger bolts (up to M30) and a thicker conical part for ground contact, offering sturdier construction.

3. Other Types

There are also variants with rubber on the ground contact surface to prevent scratches, as well as those offering anti-vibration and anti-slip benefits.

Other Information on Leveling Feet

1. Working Precautions

Leveling feet are often made from strong stainless steel. However, the risk of galling or welding of threads due to frictional heat can occur when tightening bolts under heavy loads. To prevent this, applying a fluorine spray to the threads is recommended. Additionally, using a nut in conjunction with the bolt ensures stable height over time.

2. Bolt Length

Long bolts can compromise rigidity in the bolt area, especially if a significant off-ground height is required. In such cases, extending the bolt fixing section is advisable to maintain structural integrity.

What Is a Vacuum Pen?

A vacuum pen is a specialized tweezer-like tool that uses suction to pick up small or spherical parts that are typically difficult to handle. These tools operate using a pump or similar mechanism to create suction.

There are two main types of vacuum pens: electric pump-operated and portable. Electric pump models include battery-operated and power-operated variants, while portable pens are more compact but offer less suction power. Vacuum pens are known for their ability to hold items weighing up to 4oz, although their capacity to adsorb can be affected by dust clogging the internal filter.

Uses of Vacuum Pens

Vacuum pens are commonly used for handling small precision parts in various industries. They are particularly useful for manipulating semiconductors and electronic components during transportation and assembly processes, such as surface mounting and board mounting. In addition to electronics, they are utilized in the inspection and maintenance of analytical instruments, semiconductor inspection equipment, precision instruments, the watchmaking industry, and jewelry making. Specialized vacuum pens are also available for handling wafers.

Principle of Vacuum Pens

Operating a vacuum pen is straightforward: position the nozzle over the item and lightly touch it to create suction. To release the item, simply use the release lever or button. The pen’s nozzle can be fitted with a conductive silicon rubber pad for more stable suction. The size of the pad correlates with the weight of the object it can lift, and its conductive properties help prevent static electricity.

Vacuum pens come in various designs, including models with straight or curved nozzles. Battery-operated types are generally more compact, while power-operated models are larger. The pens are categorized based on their suction mechanism: those connected to an external pump, those with a built-in pump, and manual non-pump types. Pump-connected and built-in pump types offer more powerful suction compared to the non-pump versions, which create suction by manually reducing air chamber pressure.

What Is a Muff?

A muff is a type of fitting used to connect and secure apparatus like a crumb or an O-ring to a support column. Its simple design allows for easy assembly and disassembly, making it adaptable for various experimental setups. However, selecting the correct muff size is crucial to ensure stability, as an oversized muff may lead to loosening of screws and potential equipment failure.

Zinc alloy is a commonly used material for muffs, but for chemical resistance applications, stainless steel options are also available, albeit at a higher cost.

Uses of Muffs

Muffs are primarily used in laboratory settings to fix separating funnels or to maintain test tubes at specific angles. They play a key role in experimental apparatus assembly by securely attaching a crumb or O-ring to a support column.

Their design typically includes two perpendicular grooves or holes to accommodate rod-shaped components. By threading a support post through one slot and the handle of a crumb through another, muffs enable perpendicular attachment of these components to the support column.

Principle of Muffs

Muffs feature a groove or hole for inserting a rod and a screw mechanism for secure attachment. When selecting muffs, consider the following:

1. Applicable Pipe Diameter:
   Choose a muff with a groove diameter that closely matches the diameter of the rod to be fixed. A groove too large can lead to instability, while one too small won’t accommodate the rod.
2. Screw Functionality:
   Regularly inspect muffs, especially those made of zinc alloy, for loose screws and signs of wear or corrosion. Proper maintenance, including washing and drying after use, extends their lifespan. For long-term use in chemical-rich environments, stainless steel muffs, though more expensive, offer greater durability and safety.

Stainless steel muffs, more chemically resistant than their zinc alloy counterparts, are a safer choice for extended use in environments with potential chemical exposure, despite their higher cost.

What Are Hand Lappers?

Hand lappers are tools featuring an abrasive surface attached to a rod that are designed for manually polishing, smoothing, or grinding of surfaces. Also known as hand horns or hand stones in some contexts, these tools are ideal for detailed polishing and finishing tasks. They come with a variety of abrasives and particle sizes for different effects, providing a cost-effective solution for smaller jobs compared to motorized or mechanical polishing equipment.

While hand lappers are economical, their manual operation requires more time and effort, especially for larger surfaces. Users should take breaks to prevent fatigue and need proper skills and experience for effective use.

Applications of Hand Lappers

Hand lappers are versatile and used in metal processing, woodworking, automobile maintenance, and stonework for finishing and polishing tasks.

1. Metal Processing

Useful for finishing metal surfaces, removing weld seams or burrs, thus enhancing the appearance and strength of metal parts.

2. Woodworking

Hand lappers achieve smooth wood surfaces for furniture, cabinets, and crafts, rounding edges and eliminating irregularities.

3. Automobile Maintenance

Crucial for polishing vehicle bodies, repairing scratches, and enhancing appearance, especially after paint jobs.

4. Stonework

Essential for polishing and finishing stone surfaces in buildings and monuments, adding patterns and decorative touches.

Principles of Hand Lappers

Hand lappers work by applying abrasive particles against the target surface, using friction to remove irregularities, scratches, or dirt, resulting in a smooth and polished finish. The choice of abrasive material and the applied pressure are key to achieving the desired results.

How to Select Hand Lappers

Selection criteria include grain size, types of abrasives, and handle length, affecting the finish quality, material suitability, and user comfort:

1. Grain Size

Grain size indicates the abrasiveness level, with higher values providing finer finishes. Selection ranges from rough (#240) to precision (#400 or higher).

2. Types of Abrasives

Boron carbide, with a Mohs hardness of 9.497, is a common choice for its durability, second only to diamond and cubic boron nitride. Diamonds are used for precise tasks, while alumina or ceramic abrasives are popular for general use.

3. Handle Length

The handle’s length influences usability; longer handles are beneficial for large areas, whereas shorter handles offer better control for detailed work.

What Is an Anti-Static Agent?

An anti-static agent is a substance used to prevent the generation of static electricity on the surfaces of insulators like plastics and synthetic fibers. Static electricity can attract dust and pollen, leading to stains, discomfort, or even malfunctions in home appliances and electronic equipment. Anti-static agents are applied to avoid these issues.

 In addition, electrostatic attraction and repulsion between charged objects often cause problems in manufacturing processes. An Anti-Static agent is used to avoid such problems caused by static electricity.

There are two main types of anti-static agents: coated antistatic agents applied to molded plastic products or films, and kneaded antistatic agents mixed into the product material.

Uses of Anti-Static Agents

Anti-static agents are used in various industries, including electrical products, automotive, paper, textiles, printing, resins, films, plastics, and electronics. They serve dual purposes: improving product performance and enhancing productivity during manufacturing.

1. Uses of Anti-Static Agents to Improve the Performance of Products

• Prevention of dust adhesion and static electricity on furniture and clothing
• Preventing dust from adhering to home appliances and electronic devices, and preventing damage and malfunctions caused by static electricity
• Preventing static electricity from adhering to plastic parts of cars, interior linings, engine covers, and intake parts inside air intake boxes.
• Prevention of static electricity on electronic equipment carrying cases and cushioning materials
• Prevention of adhesion of films, etc.
• Prevention of powder adhesion to bags containing powder

2. Uses of Anti-Static Agents for Productivity Improvement

In some cases, anti-static agents are removed in the post-process to improve productivity, while in other cases, anti-static agents are left in place to improve product performance.

• Anti-static in spinning, drawing, and spinning processes in textile manufacturing
• Preventing films from sticking to each other in the film manufacturing process

Principle of Anti-Static Agents

Anti-static agents are applied to plastics (surface treatment) or incorporated into plastics to improve the ion conductivity of the plastic surface or the plastic itself. This is because improving ion conductivity makes plastic surfaces less likely to become charged.

Although there are ways to improve the electronic conductivity of objects to prevent plastics from becoming charged, most Anti-Static agents improve ionic conductivity.

Improving electronic conductivity is also an extremely effective means of antistatic. However, it requires the application of metal plating to the surface of the plastic or the addition of conductive fillers with high electronic conductivity, such as carbon black or metal powder.

However, most of these treatments are limited to applications where black or metal coloration is acceptable since carbon or metal coloration will be applied to the plastic surface.

Mechanism of Action of Anti-Static Agents

Anti-static agents make plastic surfaces less likely to be charged with static electricity by making the plastic surfaces more susceptible to static electricity by the presence of anti-static agents. There are two types of application methods: application type and knead-in type.

Anti-static agents of low molecular weight type such as antistatic agents are mainly used, while anti-static agents of a high-molecular-weight type such as polymers with ion conductive moieties in their molecules are used in the kneaded-in type.

1. Coating-Type Anti-Static Agent

Anti-static agents are applied to the surface of molded plastic products and release static electricity by adsorbing moisture into the air. However, since it is only applied to the surface, it is removed by wiping with water when cleaning, etc., and has low durability.

2. Baked-in Low-Molecular-Weight Anti-Static Agent

Anti-static agents are designed to ooze onto the surface of plastics when kneaded into them. After the plastic is molded, a film of anti-static agents is formed on the surface, and moisture is adsorbed to this area to release static electricity. Therefore, the amount of antistatic agent kneaded into the plastic is as low as 0.2~2% to be effective.

As with the coating type, the anti-static agents are easily removed by wiping with water. However, as long as the anti-static agents remain inside the plastic, they will reappear from the inside, thereby restoring the anti-static properties.

3. Kneaded Polymeric Anti-Static Agents

Unlike the low-molecular-weight type, the molecular size of the kneaded-in polymer anti-static agents is large, so there is no oozing effect. Therefore, it is necessary to have the required amount present on the surface immediately after molding.

Although it is necessary to knead in a considerable amount of 5~20%, it is firmly incorporated into the plastic, and the attractive point is that it will not be wiped off with a simple water wipe. Therefore, it has the longest-lasting effect.

Types of Anti-Static Agents

As for the types of anti-static agents, as mentioned above, each type has different features and optimum applications, so appropriate selection must be made depending on the situation.

What Are Curing Sheets?

Curing sheets are protective materials used to shield surfaces from paint splashes and adherence during painting tasks. Employed across construction sites, remodeling projects, and by painting professionals, these sheets significantly enhance work efficiency and quality. Their primary function is to safeguard surfaces such as walls and floors from paint, thereby preventing accidental stains and scratches while minimizing cleanup efforts post-project.

These sheets also enhance safety by mitigating the risk of paint splattering and airborne particulate spread. Typically lightweight and manageable, they can be easily cut to size and positioned as required. Additionally, the availability of washable and reusable curing sheets offers an economical and environmentally friendly option. However, due to their low air permeability, it’s crucial to ensure proper ventilation when using them with highly volatile paints.

Applications of Curing Sheets

Curing sheets find use in diverse construction and painting tasks, providing essential protection and cleanliness. Below are key applications.

1. Construction and Painting

Utilized during painting tasks to encase walls and ceilings, curing sheets prevent paint from splashing or dripping onto these surfaces. They also safeguard flooring from paint and construction debris, preventing potential damage or the need for costly repairs.

2. Paint Mixing Areas

These sheets cover workspaces within paint mixing areas to avert paint splashes and spills, thereby maintaining a clean and secure environment.

3. Outdoors

Beyond indoor usage, curing sheets are invaluable for outdoor painting and construction, offering protection against the elements and preventing contamination of the surrounding area.

4. Automobiles

During auto painting, curing sheets envelop the vehicle’s body to protect it from paint splatter and damage, ensuring a flawless finish while also covering windows and wheels for added protection.

How Curing Sheets Work

Constructed from impermeable films, curing sheets typically comprise a base material like polyethylene (PE) or polypropylene (PP), known for their durability and water-repellent properties. These materials prevent paint and moisture penetration, ensuring the protected surface remains clean and dry. Special treatments to one or both sides of the sheets enhance their utility by reducing slipperiness and maintaining transparency for those products that require it.

Types of Curing Sheets

Diverse types of curing sheets cater to specific needs and applications in painting projects.

1. Polyethylene Sheets

These sheets range from transparent to translucent and come in various thicknesses, accommodating a broad spectrum of painting needs both indoors and outdoors.

2. Non-woven Fabric Sheets

Composed of heat-bonded non-woven fibers, these sheets exhibit enhanced tear resistance compared to their plastic counterparts and are flexible enough for application on curved surfaces.

3. Corona-Treated Sheets

These are plastic sheets treated with a corona process on one side to increase surface energy, thereby improving paint adhesion and effectiveness in capturing paint on the sheet’s surface.

What Are Aluminum Profiles?

Aluminum profiles are materials made from aluminum alloys that are designed for use as structural components in machinery and equipment. These profiles often have a hollow, four-sided shape with grooves or other features, allowing for easy connection through screws, welding, or other methods. This design facilitates the creation of lightweight yet robust structures capable of handling significant loads.

Thanks to their ease of processing and low density, aluminum alloys are widely used across various fields. In everyday applications, aluminum profiles serve as frames for screen and storm doors, offering benefits such as light weight, ease of handling, and simple disassembly.

Applications of Aluminum Profiles

Aluminum profiles find extensive use in industrial settings, including machine racks, storage racks, and steps. They are also integral to constructing room frames for safety fences within factories or for enclosing and partitioning equipment.

For industrial machinery, aluminum profiles enable the customization of frames and conveyor paths to fit specific installation sites, simplifying the creation of tailored solutions.

Design Principles of Aluminum Profiles

Aluminum profiles boast a flexible and lightweight design, simplifying the assembly of structures. Their hollow quadrilateral shape, complemented by grooves and other configurations, optimizes weight without compromising strength. The structural integrity is influenced by the material’s Young’s modulus and the profile’s shape. Although aluminum alloys have a Young’s modulus roughly one-third that of steel, their density is also about one-third, allowing for structures that are both lighter and comparably strong.

Many aluminum profiles are equipped with user-friendly nuts and easy-to-install brackets, enhancing their convenience. These profiles, typically made from 6000 series aluminum alloys like A6N01S-T5 and A6063S-T5, are valued for their corrosion resistance and weldability.

Understanding the Strength of Aluminum Structural Profiles

Types of Strength in Aluminum Frames

Aluminum structural materials are increasingly recognized as viable alternatives to steel, available from home improvement stores and online retailers. It’s crucial to understand the distinctions in aluminum frame strength, categorized into single strength and box strength to ensure their safe and effective use.

1. Single Strength
This refers to the load-bearing capacity of an individual aluminum frame, such as that of a clothesline. The allowable load is determined by the frame’s deflection, which is the extent of bending under a central load. Manufacturers typically recommend a maximum load that causes no more than 1/1,000 of the frame’s length in deflection. For instance, a 1-meter clothesline can safely support a deflection of up to 1 mm. Exceeding the recommended load may not cause immediate damage but can compromise long-term durability.

Limit load represents the breaking point of an aluminum frame, a value that varies significantly based on the frame’s dimensions. The size and length of the frame affect both deflection and limit load, with longer or smaller frames showing greater variability in these metrics.

2. Box Strength
Contrary to single strength, box strength measures the load a structure can bear when aluminum frames are assembled into a box-like configuration, such as a rack or shelf. This type of structure generally offers higher strength since the load is distributed across the entire assembly.

Box strength calculations consider deflection and a safety factor to account for the risk of fracture, with a recommended safety factor usually between 4 to 5. The strength is defined by the maximum load that can be supported with a deflection of 1/1,000 the length of the frame, facilitating easy selection of suitable frames based on specific requirements.

What Is a Digital Torque Wrench?

A digital torque wrench is a precision tool that uses electronic components to measure and adjust the torque applied to fasteners, such as bolts and nuts. Unlike analog torque wrenches, digital models display torque readings on a screen, minimizing operator error and allowing for precise torque settings and easier operation.

Uses of Digital Torque Wrenches

Digital torque wrenches are crucial in applications requiring precise torque control, including automotive maintenance, aircraft assembly and maintenance, and construction. They ensure the proper tightening of fasteners, contributing to safety and reliability.

Principle of Digital Torque Wrenches

These tools feature a torque sensor, data processing unit, and digital display. The sensor detects torsion and converts it into an electrical signal, which is processed and displayed as a torque reading.

How to Select a Digital Torque Wrench

Key considerations include power supply (battery life and recharging options), direction of load (single or dual direction measurement), torque range (suitable for specific tasks), and accuracy (higher precision compared to analog wrenches).

Other Information on Digital Torque Wrenches

Calibration is essential for maintaining accuracy. It involves comparing the wrench’s readings against known weights to ensure it remains within the specified accuracy range, typically measured in Newton meters (Nm).