月: 2023年3月

What Is a Wire Electrode?

A wire electrode is a tool used in wire Electrical Discharge Machining (EDM) machines.

During EDM, a voltage is applied between the workpiece and the tool electrode, resulting in an electrical discharge phenomenon. The high heat generated during this process (approximately 7,000°C) gradually heats and melts the workpiece.

The tool used in this process is a wire electrode, typically with a diameter ranging from approximately 0.05 to 0.3 mm, making it an extremely thin metal wire. The primary material used for electrode wires is usually brass, which is an alloy of copper and zinc.

Uses of Wire Electrodes

Wire electrodes are employed for cutting various hard metal parts. EDM can be performed on any hard workpiece that can conduct electricity.

1. Special rings processing: Achieving high-precision cuts in special rings using wire electrodes.
2. Plate springs: Cutting plate springs in layers using wire electrodes.
3. Metal masks: Easily processing metal masks.
4. Home appliances and more: Utilized for precision machining of metal components used in home appliances and smartphones. Also, applied for precision parts processing in the aerospace industry.

Features of Wire Electrodes

Wire electrodes employed in wire EDM machines cut the workpiece metal similar to a “hacksaw” through heat generated by electric discharge while continuously feeding the wire as an electrode. The choice of wire diameter depends on the shape and thickness of the metal to be cut or shaped, with wire diameters of 0.1 to 0.3 mm being commonly selected.

The wire diameter must match the die’s diameter used in the electrical discharge machine. If the wire is too thick, it will not pass through the die, and if it is too thin, the electrode wire will sway. Common wire diameters (in mm) include 0.02, 0.03, 0.05, 0.07, 0.10, 0.15, 0.20, 0.25, and 0.30.

The main material for wire electrodes is brass, which is an alloy of copper and zinc, typically with a zinc composition of 35-40%. Brass exhibits good discharge characteristics and is widely used as a general-purpose electrode wire.

Another type of wire electrode is known as “coating wire,” where the surface layer of brass is electroplated with high-purity zinc. The high-purity zinc layer ensures a uniform and smooth finish on the workpiece surface, allowing for high-speed processing.

What Is a Clipboard Holder?

Years ago, clipboard holders were essential tools for carrying drawings.

Before the advent of CAD systems, drawings could not be sent digitally as DXF or PDF files like today. They were printed and needed to be carried without bending, as distortion could lead to inaccuracies in measurements or part identification.

Drawings were therefore commonly transported in clipboard holders to maintain their integrity.

While their use has declined with digital advancements, clipboard holders still have a place in storing electrical drawings within control panels.

Uses of Clipboard Holders

Clipboard holders are now primarily used for storing specifications and electrical drawings inside control panels, cubicles, and operation panels.

Given the complexity of control and operation panels, which house numerous wires connected to breakers, magnets, relays, PLCs, and other devices, tracing each wire can be challenging.

Drawings, therefore, are crucial for checking line numbers and other details during installation. They are kept in clipboard holders for easy and immediate access.

Principles of Clipboard Holders

Clipboard holders are typically designed as box-like containers mountable inside control panels.

Available in various depths and heights, their size depends on the quantity and dimensions of the drawings they need to accommodate. The suitable size is determined by the specific application.

Many clipboard holders can be attached using double-sided tape, allowing for installation even in pre-assembled control panels.

Leaving drawings and documents loose in a control panel is not only unsightly but also risky. Contact with high-voltage lines can lead to short circuits or, worse, fires. While a tripped breaker may be a minor inconvenience, a fire can lead to severe consequences.

Thus, storing drawings in clipboard holders is necessary to prevent such hazards. Additionally, the complex wiring in electrical panels can be challenging to understand without detailed knowledge. Having drawings readily available is extremely helpful during any work on the control panel, such as modifications or additions.

What Is a Static Charger?

A static charger is a device that generates static electricity, creating a static charge on an object.

Static electricity can be problematic in many environments and products, potentially causing sparks and noise in electronic equipment. Consequently, devices like ionizers that remove static electricity, and products designed to prevent static build-up, are in widespread use.

However, static electricity can also be beneficial, enabling objects to adhere to each other. Static chargers are employed to intentionally generate static electricity for this purpose.

Common forms of static chargers include gun-like devices known as charging guns and bar-shaped chargers called charging bars.

Uses of Static Chargers

Static chargers are utilized to generate static electricity, which can then charge objects, causing them to attach or adhere through static force.

These chargers can impart a charge to even insulating materials, such as paper, vinyl, and film. These materials can then adhere to conductive surfaces like metal or glass without the need for adhesives or tapes, as the adhesion is facilitated by electrostatic charge.

They are also used in the suction of powders, including plastics and ceramics.

Principles of Static Chargers

Static chargers typically operate on the principle of corona discharge.

Under normal conditions, air acts as an insulator. However, when a high voltage is applied to an insulating gas, part of it becomes ionized, producing electrons and ions. The movement of these charged particles creates an electric current, turning the insulating gas into a conductor.

As the voltage increases, the kinetic energy of the electrons from ionization also rises. Once these electrons reach a certain energy level, they can ionize neutral molecules upon collision. This process leads to a chain reaction of ionization, resulting in a rapid increase in electric current and the emission of light and sparks, known as corona discharge.

In a static charger, when the voltage at the discharge pole is raised to create a corona discharge, the surrounding air is ionized, generating a large number of ions. These ions, when attached to a target object, charge it.

What Is a Sealing Cap?

A sealing cap is a lid that seals a hole that has been drilled for processing reasons. These caps are vital for maintaining the integrity of the hole and preventing external contaminants.

The materials used for sealing caps include rubber and metal, chosen for their excellent oil and heat resistance. For larger spaces, the cap may be embedded and secured externally with a stop ring. Ensuring airtightness and ease of removal is crucial. Designed to prevent the ingress of foreign matter and the leakage of stored lubricants, these caps boast high heat and abrasion resistance. There are various types of sealing caps, ranging from easy-to-open designs to those tailored for specific uses like closing the ends of flexible pipes.

Uses of Sealing Caps

Sealing caps are widely used across various machinery, including automobiles, construction and agricultural machinery, and machine tools. In construction, they serve to close pipe ends and safeguard flow sensors. In the electrical and electronic sectors, they protect connectors when not in use. Additionally, sealing caps find use as lids for liquid containers, such as those containing chemicals and oils, and as specialized lids for various packaging containers.

Other Information on Sealing Caps

Sealing Cap Variants

The term “cap seal” closely resembles “sealing cap” but specifically refers to a film-like seal used over bottle caps, commonly seen on wine or sake bottles. It may also denote the sealing rubber material inserted inside the cap or into the threaded part of the cap, enhancing the seal’s effectiveness.

What Is a Runner Chuck?

A runner chuck is a chuck that grips the runner and removes the molded product from an injection molding machine. Molten resin, injected from the nozzle of an injection molding machine, is fed through a thick passage in the mold called a sprue, through a narrow passage called a runner, and finally through a place called a gate to the molding section.

Normally, a runner chuck is used to grip the runner and remove the molded product. However, it can also be used to chuck the molded product itself or the sprue.

Uses of Runner Chucks

Runner chucks are commonly used in injection molding machines where robots automate the removal of molded products. To facilitate this automation, several slide rails are combined, allowing the runner chucks to move along these rails.

Typically, a runner chuck clamps a runner between two claw-shaped metal fittings. It operates either electrically or pneumatically. Chucks with sensors on the jaws are generally used to monitor operation and facilitate the transition to subsequent steps.

Features of Runner Chucks

The method of removing molded products from a mold depends on the shape of the gate, the entry point to the molded product in the mold. In the direct gate method, where the sprue is directly connected to the gate at the center of the molded product without a runner, the molded product itself or the sprue is chucked. This method leaves large gate marks, necessitating post-gate-cutting finishing.

When the gate is connected to the side of the molded product via a runner, use runner chucks or chuck the sprue. Gate marks remain on the molded product, requiring finishing after gate cutting.

In the submarine gate method, where a tunnel-shaped gate is provided at the end of the runner, both the molded product and the runner are chucked. The gate is automatically cut when the mold opens, eliminating the need for post-molding processing.

In the pin gate method, which involves using three molds to separate the molded product from the runner, the molded product is chucked, and runner chucking may not be necessary. The runner and sprue, including the pin gate, are separated from the mold at the first mold split, and the molded product is removed in the subsequent split operation. The gates are automatically cut with the mold split, so post-molding gate cutting is not required.

What Is a Millsaw File?

A millsaw file is a specialized file designed for sharpening various metals, including copper, silver, gold, and iron. It is versatile and capable of being used on both hard metals and softer materials like plastic and wood.

This tool is essential for metalworking due to its ability to sharpen hard metals. There are multiple shapes of millsaw files, each suited to different applications. For sharpening particularly hard metals, like stainless steel, a specialized millsaw file is required.

Uses of a Millsaw File

Millsaw files are primarily used for sharpening metals. They are helpful when fitting metal parts together, especially if one part is too large. By sharpening the oversized part with a millsaw file, it can be adjusted to fit. For enlarging holes, a long, round millsaw file can be used effectively.

These files are also instrumental in surface treatment tasks, such as smoothing uneven surfaces or removing burrs from metal edges post-cutting. Moreover, they are useful for removing rust from metal parts and stripping paint from metal surfaces. Millsaw files are also employed in the sharpening and maintenance of saw blades.

Principle of a Millsaw File

A millsaw file features a bladed surface that scrapes off material softer than itself. This process smoothens or shapes the material being filed.

Available in rough, medium, and fine grits, millsaw files offer varying levels of sharpening. Rough grit is used for initial grinding, creating visible unevenness on the metal surface. To achieve a smoother finish, medium-grit files are used next, followed by fine-grit files for final polishing.

Typically flat in design, millsaw files are adaptable for various applications. Some files feature different levels of coarseness on each side, providing versatility in use. Modern advancements have introduced diamond-coated millsaw files, utilizing artificial diamonds for the effective sharpening of even the hardest metals.

What Is Airtight Waterproof Tape?

Airtight waterproof tape is a very useful tape because it can be cut by hand and is airtight and waterproof. It is often used at construction sites and in interior decorating because it can be applied to walls, ceilings, and other spaces to maintain waterproofing.

The main colors are white and black, and widths range from 3 to 5 inches. Adhesion can be single-sided or double-sided.

Airtight waterproof tape is also used to repair leaks temporarily and other problems during disasters. It can be used to reinforce window sashes and to join destroyed drywall, making it easy to use and convenient to have one in the home.

Uses of Airtight Waterproof Tape

Airtight waterproof tape is often used to reinforce and protect seams at construction sites. It is also used to seal the joints between layers of insulation sheets, moisture-permeable tarpaulins, and other materials.

In some cases, it is used as an alternative to butyl tape.

Due to its durability and ease of use, it is widely applied in DIY and gardening. Note that the heat resistance temperature varies depending on the product, and the adhesive may deteriorate due to direct sunlight.

Principle of Airtight Waterproof Tape

The airtight waterproof tape consists of a nonwoven fabric on the top surface, with reinforcement, adhesive, and release paper underneath.

Nonwoven fabrics made of polyester, polyethylene, or PET resin are often used as the base material for airtight waterproof tape. In the case of polyester non-woven fabrics, paints can be applied over them so that they can be treated inconspicuously. Products with urethane foam sandwiched between them have high heat insulation properties. In addition, products made of aluminum material have high heat resistance. Aluminum material is also weather-resistant and suitable for repairing exterior walls. However, since it cannot be cut by hand, a cutter or similar tool is required.

Butyl and acrylic adhesives are used. Acrylic-based adhesives are easy to cut by hand, so workers’ hands do not need to get dirty. It also has the characteristic of being difficult to peel off even outdoors. It should not be reapplied, as the adhesive’s adhesive strength will decrease.

The airtight waterproof tape has very high adhesive strength and is durable, and some products can withstand 50 years equivalent of use.

What Is a Ratchet Screwdriver?

A ratchet screwdriver is a screwdriver with a ratchet mechanism.

Screwdrivers are used to tighten or remove screws by turning them slightly by hand. In this process, an ordinary screwdriver requires the user to change grips gradually.

Ratchet screwdrivers, however, do not require the handles to be changed, and screws can be tightened or removed only by repetitive movements.

Uses of Ratchet Screwdrivers

Ratchet screwdrivers are used for tightening and removing screws. They are used in a wide range of applications, from product manufacturing to DIY, but are most often used to increase work efficiency.

When assembling equipment, there are cases where there is not enough space for tightening screws, and in such cases, ratchet screwdrivers with a special shape are used.

Ratchet Screwdriver Principle

The ratchet mechanism is a system that rotates in one direction only and spins out when rotated in the opposite direction. The ratchet screwdriver is an application of this ratchet mechanism to a screwdriver.

Ratchet screwdrivers, while convenient, are a bit more difficult to handle. When tightening a screw, the screw may not be tightened because it moves along with the rotation of the ratchet.

One way to avoid such failures is to move the ratchet screwdriver while holding the screw in place with your other hand. Some experience is required to handle the ratchet screwdriver successfully.

Types of Ratchet Screwdrivers

Ratchet screwdrivers are classified into the following six types according to their shapes.

• General screwdriver type
• Ball Grip Type
• T-handle type
• Stubby Type
• Plate Ratchet Type
• Flexible Type

It is important to select a product that is easy to use according to the work environment.

1. General Screwdriver Type

The general screwdriver type is a ratchet screwdriver with a long, thin grip. Many products can store bits in the grip section. Bits such as Phillips, flathead, hexagonal, and Torx are attached to the tip of the screwdriver. 

2. Ball Grip Type

The ball grip type ratchet screwdriver has a ball-shaped grip that is easy to grasp. It is easy to use and improves work efficiency.

Many products use a long, replaceable bit that is inserted into the grip section, rather than a short bit that is attached to the tip as in the general screwdriver type. In addition to the bit-mounting type, there are also products with fixed types and sizes, such as plus and minus bits.

If the screw to be worked on is fixed, the fixed type allows more stable work and eliminates the risk of losing bits.

3. T-Handle Type

Some ratchet screwdrivers have a T-shaped grip. The large area at the top of the handle allows the user to apply force with the palm of the hand from above. When used correctly, the screwdriver is resistant to tampering with screw threads even when tightened with high torque. Some products can store bits in the handle.

4. Stubby Type

The Stubby type is a ratchet screwdriver with a short grip. It is too compact and more difficult to grip than other types, but it is useful for tightening screws in confined spaces. 

5. Plate Ratchet Type

The plate ratchet screwdriver is a low-profile ratchet screwdriver. It is also called an offset ratchet screwdriver. Because the head is small, it can handle screws in narrow or deep places. It is difficult to apply force from above, and care must be taken not to damage the screw threads when using it.

6. Flexible Type

The flexible type is a ratchet screwdriver with a long, flexible tube-like tip. It can access screws in very deep places that even the stubby type or plate ratchet type cannot reach.

Also, using a bit with a magnetic tip is convenient and safe, as the screw will stick to the bit and prevent it from falling.

What Are Silicone Gels?

Silicone gels, also known as anti-vibration gels, are materials designed to absorb or dampen vibrations. These viscous compounds disperse energy, reducing vibration’s impact on buildings, machinery, and other structures, thus extending their lifespan and enhancing comfort.

Uses of Silicone Gels

Silicone gels find extensive application in construction, manufacturing, and telecommunications to mitigate vibrations. They are instrumental in enhancing the seismic resistance of buildings, improving machinery longevity in production lines, and safeguarding data center equipment against vibrations.

Principle of Silicone Gels

Comprising primarily silicone, rubber, or other polymers, silicone gels absorb vibration energy, reducing its transmission. These materials are capable of dispersing vibration across a broad area, diminishing its intensity, and in some cases, converting vibration energy into thermal energy.

Types of Silicone Gels

Available in various formulations, silicone gels include silicon-based gels known for their durability and temperature resistance, polyurethane gels that offer superior vibration isolation, and natural rubber-based gels valued for their flexibility and longevity.