An Engineer’s Guide to CNC Turning Centers

Basics of turning center please check out below:

 

Lathes vs. Turning Centers: What’s the Difference?

You’ve probably seen the terms ‘CNC Lathe’ and ‘CNC Turning Center’ used interchangeably.

 

“[They’re] basically the same thing in my book,” said David Fischer, lathe product specialist at Okuma America Corporation.

 

Nevertheless, while there is no formal distinction between lathes and turning centers, the former term is often used to refer exclusively to simpler machines—those designed for turning operations alone. In contrast, the term ‘turning center’ usually denotes machines which integrate milling or drilling capabilities, or those with sub-spindles for performing secondary operations.

 

“In my opinion, a CNC lathe just strictly does turning; it’s a 2-axis lathe with X and Z axes and typically only one chuck,” said Rick Bramstedt, product manager for Mazak’s Advantec division. “A CNC turning center has milling capability, or a second spindle plus milling capability, and so it might have a Y-axis as well. We also call those Multi-Tasking Machines. That’s how I see turning centers: they offer more than just turning.”

 

Marlow Knabach, Chief Technology Officer for DMG MORI USA, agreed:

“I see it as the evolution of the lathe,” he said. “Most people called it a lathe in the past, but as CNC became more elaborate and with the addition of milling and sub-spindles, it evolved into a CNC turning center.”

 

Whether you’re working on a lathe or a turning center, the basic parts are the same.

 

Turning Center Configurations

“You have essentially two different types of CNC machining centers: the traditional, horizontal type that’s been around for quite some time, and then you have the vertical type, which spins the part like a top instead of spinning it like a car tire,” said James Petiprin, key account manager for EMAG, LLC.

 

“Horizontal probably makes up 60 or 70 percent of the market because it’s been around longer—every machinist learned on a horizontal lathe.”

 

Horizontal Turning vs. Vertical Turning

CNC turning centers come in either horizontal or vertical configurations. There are also inverted vertical turning centers, which reverse the position of the spindle and the chuck. All three machine types generally consist of the same basic components (i.e., headstock, carriage, etc.), but differ in their orientation. Deciding whether to opt for a horizontal, vertical or inverted vertical lathe depends on a host of factors, but there are some rules of thumb that can help you make the decision.

 

“The advantage with a horizontal lathe is that gravity pulls the chips away from the part,” said Knabach. “In other words, as you’re turning, all the chips fall down into the chip conveyor or bin.”

 

“The advantage of a vertical lathe is that gravity helps seat your part into your workholding,” he continued. “But the chips can be an issue, especially if your part is concave, since it can trap the chips internally. So you have the possibility of re-cutting your chips. The other concern with a vertical lathe is that the chips fall down into the spindle itself, so your guarding has to be extremely efficient.”

 

“Generally, horizontal lathes are more flexible since they can have longer bed lengths relative to spindle size,” said Fischer. “They can also use barfeeders and commonly have tailstocks, a rarity on verticals.  On the other hand, if you are machining large diameter short parts, especially if they are heavy parts, the vertical lathe works well.”

 

“It’s primarily part size; that’s the biggest factor that determines between the two,” said Bramstedt. “When we look at small turning applications, a lot of automotive turning applications (transmission gear blanks, brake rotors, etc.) are done vertically and typically with a twin spindle. One benefit of that is that you have gravity working for you; when you put the part in the chuck, it seats itself. Another benefit is chip flow, again thanks to gravity—all the chips tend to fall away from the part into the pan or conveyor.”

 

“I’ve seen 30-inch diameter parts run on a horizontal machine,” he added, “but loading it is tricky because you need to push the part into the chuck and then hold it while you’re clamping it.”

 

Another factor to consider when choosing between horizontal and vertical configurations is the extent to which your turning center will be automated. “Horizontal lathes are usually easier [to automate] since the spindles and/or tailstock are at opposite ends of the machine and the turret can be positioned in such a way as to present minimal clearance issues,” said Fischer.

 

Getting the Most from Your CNC Turning Center

Lathes have been around for most of human history, and with good reason. Although the underlying technology has continued to advance, turning operations remain a vital part of many manufacturing processes.

 

That being said, turning is just one aspect of manufacturing among many.

 

For more information on turning centers, visit the websites for FALCON Machine Tools Co., Ltd. – the manufacturer of great rigidity and infallible precision turning machines.

 

Article Source: engineering.com

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The Value Proposition of Five-Axis Machining

Moving to five-axis machining is a big commitment. What exactly are the concrete benefits of five-axis machines compared to three-axis machines?

 

The “five” in five-axis machining refers to the number of directions in which the cutting tool can be oriented as it approaches the part surface. This maneuverability provides almost unlimited possibilities for the type and shape of parts one can effectively machine. A significant advantage of five-axis capability is being able to process five sides of a part in a single setup. All sides are accessible except the one resting on the table. For this reason, shops that don’t have full five-axis work involving complex shapes can still benefit greatly from the five-sided machining a five-axis unit allows.

 

If parts being produced on a three-axis machine must be flipped over or repositioned, producing them on a five-axis machining center in one setup may be more profitable. Most often, the process on a three-axis VMC requires flipping the part, or rolling it around from fixture to fixture, to access all sides the part. Unfortunately, whenever the operator must open the door of a VMC to flip or rotate the part for this purpose, or to load or unload the part, remove chips, or perform in-process quality checks, the spindle must be stopped. This means that a part requiring machining on six sides may have to be moved by the operator seven times (load, reposition five times, unload). Five-sided machining eliminates these extra stoppages.

 

With five-axis machining, you can grip the part, perform all roughing operations, and then go back and finish machining—in essence, gripping the part only one time. This capability enables you to machine part features in the order that is most convenient and may make the most sense for optimum material removal. For example, a part may have neighboring features that chatter or vibrate. These features can be roughed from both sides to reduce the chatter. Being creative with the processing steps is likely to enable you to conquer more challenging features with the added flexibility.

 

Another advantage to five-sided machining must be mentioned here. If holes on a prismatic part must be located to key features with a tight tolerance, five-sided machining may enable the part to be positioned on the side that requires the least machining, leaving a high percentage of features accessible for processing in a single setup. On a highly accurate machine with five-sided capability, the position of these features will correlate. This is not usually the case when using multiple holding fixtures on a three-axis machine. Machining features in one operation reduces location errors resulting from moving the part.

 

From a mathematical or statistical process-control standpoint, process capability for, let’s say, 30 parts produced on a five-axis machine versus on a conventional machine will be higher on the five-axis machine by eliminating the human involvement required for part repositioning. Even on the most finely tuned conventional machine, slight error is introduced whenever parts are handled by the operator. Using five axes to complete a part in one cycle with little or no operator intervention avoids this source of error.

 

Having said all this, you might be surprised to learn that a five-axis machine is never quite as robust as a three-axis machine. In addition to X, Y and Z axes, the rotary tables or trunnion add more mechanical joints susceptible to flex and wear. Do not let this concern you. Most shops will use 3+2 positioning for the roughing cycle and then use full five-axis machining to finish. Position, then hog, position, then hog, then use five-axis machining to finish the part gracefully.

 

Machining molds on a three-axis machine has its own challenges and limitations. For deep-pocket molds or tall-core molds, the required tools tend to be longer and smaller in diameter. Feed rates must be slowed to minimize tool chatter and prevent breakage. In contrast, with full five-axis machining, you can use shorter, stouter tools; have better access to the surface without Z-axis interference; take heavier cuts; increase feed rates; remove more material faster; and achieve better surface finishes, all while requiring fewer setups and shorter machining times. The incremental increase in costs for a five-axis machine compared to a three-axis machine will generally be absorbed quickly through increased efficiency.

 

The current technology in today’s five-axis machines delivers greater capability. These machines always seem to get the job done faster by enabling you to do more work in a single operation. There are fewer operations to program and fewer fixtures to create, and there is less flipping of parts and less in-process movement of parts around the shop. This overall increase in shop efficiency means more money in the bank. Perhaps it’s time to start thinking seriously about five-axis machining.

 

If you have any interest in 5 axis machining center, please try to visit CNC-TAKANG Co., Ltd… It is the company of specializing in various lathe machines. You can find CNC lathes, double column machining centers, precision lathes, heavy duty lathes, and much more machinery on its website. More details, do not hesitate to check out their website and feel free to send inquiry to CNC-TAKANG.

 

 

Article Source: https://www.mmsonline.com/blog/post/the-value-proposition-of-five-axis-machining

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What is Electro Discharge Machining?

The acronym EDM is derived from Electrical Discharge Machining.

 

The EDM process we know today started with the observations of Joseph Priestly in 1770. He noticed that electrical discharges had removed material from the electrodes in his experiments. This is also known as electro-discharge erosion.

 

In the 1940’s two Soviet researchers, the Lazarenkos, developed a machining process that formed the foundation for modern EDM.

 

Electric Discharge Machining

 

The basic EDM process is really quite simple. An electrical spark is created between an electrode and a workpiece. The spark is visible evidence of the flow of electricity. This electric spark produces intense heat with temperatures reaching 8000 to 12000 degrees Celsius, melting almost anything. The spark is very carefully controlled and localized so that it only affects the surface of the material. The EDM process usually does not affect the heat treat below the surface. With wire EDM the spark always takes place in the dielectric of deionized water. The conductivity of the water is carefully controlled making an excellent environment for the EDM process. The water acts as a coolant and flushes away the eroded metal particles.

 

Wire Cutting

 

Wire cutting EDM uses a metallic wire to cut a programmed contour in a workpiece. Extrusion dies and blanking punches are very often machined by wire cutting. Cutting is always through the entire workpiece. To start machining it is first necessary to drill a hole in the workpiece or start from the edge. On the machining area, each discharge creates a crater in the workpiece and an impact on the tool. The wire can be inclined, thus making it possible to make parts with taper or with different profiles at the top and bottom. There is never any mechanical contact between the electrode and workpiece (see above). The wire is usually made of brass or stratified copper, and is between 0.1 and 0.3 mm diameter.

 

Depending on the accuracy and surface finish needed, a part will either be one cut or it will be roughed and skimmed. On a one cut the wire ideally passes through a solid part and drops a slug or scrap piece when it is done. This will give adequate accuracy for some jobs, but most of the time, skimming is necessary. A skim cut is where the wire is passed back over the roughed surface again with a lower power setting and low pressure flush. There can be from one to nine skim passes depending on the accuracy and surface finish required. Usually there are just two skim passes. A skim pass can remove as much as 0.002″ of material or a as little as 0.0001″. During roughing (i.e. the first cut) the water is forced into the cut at high pressure in order to provide plenty of cooling and eliminate eroded particles as fast as possible. During skimming (accuracy / finish cuts) the water is gently flowed over the burn so as not to deflect the wire.

 

If you want to learn more information about EDM machines, please visit Excetek Technologies Co., Ltd. They provide best quality wire cutting EDM machines, die sinking EDM machines, and small hole drilling EDM machines. Feel free to send inquiry or contact Excetek to obtain further details about Electro Discharge Machining.

 

 

Article Source: https://www.xactedm.com/edm-capabilities/how-edm-works/

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Plastic Extrusion: Advantages and Disadvantages of Plastic Extrusion

Plastic Extrusion

Plastic extrusion is the process where plastic materials are converted from solid to liquid and then it is reconstituted into finished products. In other words, plastic is melted down and then reshaped into useful items. There are some advantages to plastic extrusion, but there are also a few disadvantages that must be considered.

 

Advantages of Plastic Extrusion

3 of the major advantages of plastic extrusion are as follows.

 

  • Low Cost: Compared to other molding processes, plastic extrusion molding has a low cost and is more efficient. The extrusion molding process uses thermoplastics and they undergo repeatedly melting and hardening, this allows the waste to be reused rather than be discarded. Raw material and disposal costs are lowered. Plastic extrusion machines operate continually and this reduces the chances of inventory shortage. It also allows for 24-hour manufacturing.

 

  • Better Flexibility: Extrusion molding will provide considerable flexibility in the products being manufactured with a consistent cross section. As long as the cross section stays the same, the extrusion molding can produce complex shapes. Minor alteration to the plastic extrusion process the manufacturers can use it for plastic sheets or produce products that mix plastic attributes.

 

  • After Extrusion Alterations: Plastics remain hot when they are removed from the extruder and this allows for post-extrusion manipulations. Many manufacturers will take advantages of this and use a variety of roller, shoes and dies to change the shape of the plastic as needed.

 

Disadvantages of Plastic Extrusion

Plastic extrusion has also some disadvantages.

 

  • Expansion: Once the hot plastic is removed from the extruder it will many times expand. This is called die swell. It is problematic to try and predict the exact degree of expansion. Because it is hard to predict the exact expansion, manufacturers often accept significant levels of deviation from the dimensions of the product.

 

  • Product Limitations: Extrusion plastic molding does place limits of the types of products that can be manufactured. There are alternatives that require an investment in a different type of extrusion equipment.

 

If you have any interest in plastic extrusion machinery, I recommend that you can visit the website of Leader Extrusion Machinery Company Ltd. They have more than 20 years’ experience designing and manufacturing plastic extrusion machinery. And the company specialty is manufacture of PP, PS, PVC, PC sheet extrusion lines; and PP, PC PET hollow profile sheet extrusion lines.

 

Learn more information about plastic extrusion machines, welcome to send inquiry to Leader Extrusion Machinery Company.

 

 

Article Source: http://civilengineersforum.com/plastic-extrusion-advantages-disadvantages/

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Application of Cold Roll Forming Machine

Do You Know What A Cold Roll Forming Machine Is?

Cold Roll Forming Machine is a kind of machinery which uses the cold roll forming technology to roll forming the sheet, strip and sheet metal and so on. It makes the metal panel to form a special section bar, so the use of roll forming machine is very wide.

 

Cold-formed steel products which is produced by cold roll forming machine, is a kind of structural member is more important. It is widely used in construction, automotive, electronics and shipbuilding, machinery and other industries. In some areas, it is so popular as it can replace steel, play the effect of saving energy and resources, it is developing more and more rapidly, technology is being improved.

 

The cold roll forming machine have many types, like the gutter roll forming machine, door frame roll forming machine, downspout roll forming machine, garage door roll forming machine, solar photovoltaic support roll forming machine, heavy truck fender roll forming machine, rack column roll forming machine, cable bridge roll forming machine, carriage board roll forming machine, and so on.

 

Well, Where to Find The Reliable Cold Roll Forming Machine Manufacturer?

 

I think Yunsing Industrial that would be your best choice! Yunsing has accumulated more than 40 years of experience specializing in manufacturing steel plate automatic cold roll forming machines with advanced technologies and superior quality products, such as roofing and wall cladding, corrugated sheets, stepped tile roofing, floor decking, C-Purlin, rolling shutters and door frames.

 

If you need more information about cold roll forming machine series, please do not hesitate to visit Yunsing. They will supply you the best quality roll forming machines and services.

 

 

Article Source: https://www.linkedin.com/pulse/application-cold-roll-forming-machine-lolita-wang

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Things You Should Look at Before Buying a Pipe Cutter

1) Types of Pipe Cutters

There are various types of pipe cutters available in the market, and your choice entirely depends upon your objective.

 

Single handed pipe cutters are best when working in little spaces or for single DIY tasks, as each cutter just fits one pipe size and they are usually less expensive than the bigger adjustable cutters.

 

The second type available is the ratcheting tubing cutter which is helpful if working in narrow regions as the handle gives the apparatus additional length. It’s likewise valuable in regions where the pipe cutter may tend to tumble off the pipe.

 

Another category is the adjustable pipe cutters. These are flexible to adjust according to the requirements and perfect for frequent users who have to deal with different sized pipes regularly. Being produced using cast aluminum implies that it will have a more extended life than a plastic covered cutter and is consequently best for long term use.

 

The fourth type is called the heavy duty adjustable pipe cutter. This is the best type to cut iron pipes as it has additional cutting wheels and pressure adjustments. This is required as iron is a solid material. You ought not to utilize a similar apparatus for cutting both steel and iron pipes as the blade will become dull if used to cut both materials.

 

The last major type available is the Power pipe cutter which is immensely helpful when utilizing for a longer time span as the cutter requires little exertion from the client and is driven by batteries. Summing it up, the first thing you need to identify is your need for the pipe cutter. Therefore, your needs will determine the type of cutter you want, and you must search for h=the relevant type to waste minimum time and reach the best alternatives.

 

2) What Materials Can the Pipe Cutter Cut?

What is important to consider next is the material the pipes you deal with are made up of. There is a vast variety of pipe cutters in the market, each having variable specifications and strengths; so what you mainly need to see is that is this particular pipe cutter appropriate to deal with my pipes?

 

Henceforth, the ones not fulfilling your basic requirement are eliminated automatically, filtering your options!

 

Most of the pipe cutters have the ability to cut steel, aluminum, brass, copper and plastic pipes, so they serve as multi-purpose pipe cutters.

 

Such pipe cutters have exceptionally sharp blades to cut through materials as hard as iron and steel, while the ones specifically manufactured for PVC pipes tend to have a lesser sharp blade as the material is lighter. However, if there is an exception and you need to cut glass or concrete pipes usually used in the infrastructure, you will probably need a specialized pipe cutter which has the appropriate features to help you out.

 

3) Dimensions, Weight, and Capacity of the Pipe Cutter

Dimensions and weight is an important specification you need to be careful about. As there are millions of pipe cutters roaming around across the markets, you need to identify exactly what you need!

 

Only then can it prove to satisfy you. So after answering the first two points, you need to be watchful about the dimensions, design, and weight of the pipe cutters under consideration.

 

Ergonomically designed pipe cutters are the best as they are manufactured keeping in mind user convenience. In a similar manner, you must reach a conclusion about your preferences regarding the weight.

 

Handy pipe cutters for individual use usually weigh about 6 to 8 ounces hence they are easy to carry and use. However, some professionals who had been dealing with hand tools prefer to have heavier ones having the view that they have a nicer grip and are firm therefore the weight must match with your preference and requirement.

 

Lastly, an important feature to be considered is the minimum and the maximum diameter of the pipes that could fit in the pipe cutter. If you have to use it for thicker pipes, then you must look for a pipe cutter having a greater capacity however if you usually need to cut narrow pipes then a pipe cutter having the capacity to cut a pipe with a diameter up to 50mm would work.

 

4) How is Your Pipe Cutter Powered?

When you intend to purchase a power pipe cutter, you must closely evaluate how it is powered? And choose the pipe cutter which best suits you.

 

There is a wide range of pipe cutters driven through distinct ways! There are electrical tools, hydraulic tools, pneumatic tools and manual tools. Electrically driven pipe cutters are run by motors or batteries and are usually required for large pipes used in construction.

 

Hydraulic tools are used in similar areas and are powered by the pressure of fluids like oil while pneumatic tools are driven by the pressure of the gas and usually require compressed air for functioning. The last type is manual tools.

 

Pipe cutters are usually manually powered as they use springs, screws and knobs hence they are inexpensive, handy and suitable for personal use.

 

5) Cutting Speed of the Pipe Cutter

With the rapid increase in technology and evolving marketing techniques, it has become essential to assess the products before selling. Hence all pipe cutters have been tested before their launch for their efficiency, so are the pipe cutters.

 

The quicker the pipe cutter slices the pipe, more preferred it is. The cutting speed is also a reflection of the quality and strength of the blades it has hence it is of extreme importance to check the cutting speed.

 

The faster it cuts, the better quality blade it has so it proves to be more helpful for the users when the pipe cutter can increase their efficiency, simplify their tasks and most of all provide clean cuts! However cutting speed is mainly monitored for power pipe cutters, not the manual ones.

 

6) Additional Features

In addition to these major specifications, what you need to look at are these features. Firstly check does it have an integral reamer? This is beneficial because every user wishes to invest in a pipe cutter which would slice off the pipes neatly. Therefore, a reamer fulfills this function by cleaning the burr after the pipe has been cut, leaving behind no metal fillings to be bothered about.

 

Secondly, it is quite natural that the user would be interested in knowing its outlook before adding it to his tool box, so you need to investigate the details of the body.

 

Pipe cutters having a textured exterior are preferred more as they provide a firm grip so it is easy to use and they should be made up of a strong aluminum cast to withstand damages and last long. It should also have an ergonomic design and be in a graceful color which you like would automatically add more appeal to it.

 

Lastly, availability of Replacement cutting wheels is an additional attraction, as consumers prefer to buy pipe cutters whose replacement cutting wheels are easily available!

 

Cutting wheels tend to wear off with time hence there is a definite need of changing them, what if you end up knowing no alternate cutting blades are available for the model you have purchased?

 

Hence you must keep in mind that the pipe cutter you buy should have its replacement cutting wheels in the market for your future convenience.

 

Get more information about pipe cutter and tube cutter, try to visit the website of Maxclaw: www.maxclawtools.com – Maxclaw is the expert of manufacturing ratcheting tubing cutters, tube bending tools, double flaring tools, hook spanner wrenches, and much more. Feel free to send inquiry to Maxclaw.

 

 

Article Source: https://bestpipecutter.com/

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Toolholding 101: Top Tips for High Productivity Machining

The need for higher feed rates for high productivity machining has driven spindle speeds to levels thought impossible at the start of the modern CNC era twenty years ago.

 

Turning cutting tools faster has productivity benefits but also introduces new problems in toolholding as the physics of rotating masses become dominant. It’s just not enough to tighten a collet’s drawbar with a box wrench anymore.

 

Today, balance, form factor and multiple modes of vibration are some of the factors that must be considered if an operation needs to take advantage of the maximum performance offered by today’s machines and cutting tools.

 

Critical Tool Attributes for Good Holding

Does the cutting tool affect holding ability? More than many machinists and engineers realize. The amount of available shank for gripping is a significant factor.

 

It’s important not to forget the other factors.

 

Polished shanks reduce friction, as does the cleanliness of both the shank and tool holder. Oil and coolants reduce gripping power. Cutter shank roundness is often assumed to be close enough to perfect to ignore, but in reality a 25 millionths tolerance is necessary for high-speed performance.

 

Similarly, ISO h6 tolerance of the tool’s shank diameter is important, which for smaller tools can mean 0-6 micron repeatability. Most shops lack the ability to check low micron diameter tolerances, so a good tool supplier is essential here.

 

The Importance of Vibration

Vibration is a fact of life in dynamic systems. Whether it’s a tuning fork or an airplane fuselage, with enough energy input, multiple modes of flex will result in unwanted movement of the structure.

 

For tools spun at high speed, the problem gets worse. Centrifugal forces are set up by the imbalance of the rotating tool holder/tool assembly, which is caused by imperfect mass distribution around the spin axis. Even a set screw offset a few millimeters from center can cause a noticeable vibration at high speeds.

 

It’s a perfect storm: double the spindle speed and the forces quadruple. Since there’s no practical way to make the tool holder larger in diameter, the key to control is to minimize the offset mass. The easiest way to achieve this without dynamically balancing the assembly is to use intrinsically symmetrical tool holders.

 

Side Lock? Slow Speed Ahead

Traditional side lock end mill holders are inexpensive, quick to set up and operate, but have several disadvantages. With a TIR of .001”, poor vibration damping and weak gripping power, this traditional toolholding method is restricted to roughing operations at low speeds.

 

Shrink Fit: More Complex, But Better Performance

Shrink fitting tools would seem like the perfect toolholding technology: full contact with strong clamping forces.

 

Shrink fit tools are a good choice for moderate to heavy milling and have good speed capability, but the gripping forces are dependent on the tolerance between the tool shank and the holder inside diameter. Heavy wall holders also have superior gripping forces. Tool breakage is a frequent factor in overall shrink fit tooling costs, since broken tool shanks can’t be removed from the holder.

 

Set up time is necessarily slow with shrink fit systems as holders must be heated and cooled before use. This adds safety considerations due to burn hazards as well as the need to stock a large number of tool holders to maintain productivity.

 

Runout is five times better than side lock clamping and high-speed capability is excellent, but poor vibration damping characteristics means that the full potential of high-speed milling is limited.

 

Collet Chucks: Old Idea, Great for High Speed Machining

Most machinists start their training by screwing collet chucks into manual vertical knee mills.

 

Like a mechanical pencil, collet holding is simple, easy to understand and can generate good wedging action for strong clamping. For more sophisticated high-speed milling, however, there’s another advantage to collet-type clamping: symmetry.

 

This natural static balance helps reduce the vibration problem at high speeds, making collet chucks ideal for high feed/speed and finish milling. Compared to shrink fit clamping, tool setup is easy, fast and doesn’t require special fixtures or tools. Especially important is the runout characteristic of collet clamping: twice as good as shrink fit and 10 times better than side locking tool holders.

 

Collets are essentially a series of concentric wedges acting on the tool shank and like any wedge, the higher the applied forces, the greater the force multiplication clamping the tool.

 

Milling Chucks: All-Around Performance

For applications requiring fast tool changes combined with high grip strength, milling chucks are a good solution.

 

Milling chucks operate by cam action of multiple rows of needle bearings to apply consistent clamp forces on a collet.

 

The inclination of the needles is the key to the gripping force of a milling chuck. Like a shallow taper wedge, each element trades off fast action for a strong wedging effect. When combined with multiple elements in a multi-row needle bearing, this gives ample gripping force over a large area of a tool shank.

 

Larger tool diameters allow more needle bearing elements for even greater clamping power. High retention force combined with a simple twist-to-lock operation makes milling chucks ideal for general purpose operations. Runout, however, is reduced compared to collet chucks, but is still better than double the performance of side lock systems.

 

Hydraulic Chucks: Low Runout, Fast Tool Changing

Is there a way to combine the quick change capability of side locking systems with the excellent runout and speed of collet clamping?

 

Hydraulic clamping offers both, with the added benefit of a wider clamping range using straight collets.

 

The mechanical advantage of hydraulics offers consistent clamping force with little operator-to-operator variation and without special fixtures or tools. Hydraulics are ideal for finish milling, reaming and drilling operations.

 

Hydraulic clamping combines the best of the other methods with outstanding runout specs and is essential for precise, accurate finish work.

 

So which clamping method is ideal for your application? It depends on the most critical attributes for your operation.

 

For precise work, a low TIR may be important. For multiple setups, quick change capability may be essential for high productivity. Tool retention force may be the weak link in a tough job.

 

Which Is Best?

 

Again, it is highly task-specific and no single article can cover the full range of problems and solutions associated with advanced toolholding for high-speed milling.

 

A good tool holder manufacturer has trained personnel and technical expertise that are as important as product price and performance to high throughput shops. They’re a wealth of money saving knowledge and should be consulted for demanding jobs.

 

Learn more information about tool holder series, please do not miss the website of Shin-Yain: www.syic.com. The company provides kinds of tool holders, including shrink fit, angle head holders, boring head shank, collet holder, milling chuck, collet chuck holder, etc. Please feel free to contact or send inquiry to them. Let SYIC know your requirement of tool holders.

 

 

Article Source: https://www.engineering.com/AdvancedManufacturing/ArticleID/11710/Toolholding-101-Top-Tips-for-High-Productivity-Machining.aspx

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Advantages of Zinc Alloy Die Casting

If you’re considering aluminum die casting, there are several reasons why Zinc die casting could be a better option for you.

 

10 X’s Greater Tool Life

A Zinc die’s tooling life can be more than 10 times longer than that of an aluminum die! Lower casting temperatures for zinc are easier on tools because they create minimal thermal shock and prolong die casting tool life. With dies costing upwards of $50,000 each, having a long lasting tool can represent a significant cost savings.

 

Superior Thermal Conductivity

Zinc is a better conductor of heat than Aluminum which makes it perfect for applications like heat sinks or electrical components. This means Zinc is able to absorb and dissipate the heat better than Aluminum.

 

Low Melting Point = Cost Savings

Zinc melts at 787.2°F whereas Aluminum melts at 1,221°F. This gives Zinc an advantage because casting can use a process called “Hot Chamber” casting which is quicker as well as being less costly than “Cold Chamber” methods.

 

Faster Cycle Times = Better Pricing

Using the Hot Chamber process also gives Zinc a major advantage over Aluminum because the hot chamber process goes so much quicker than Cold Chamber. In cold chamber, Aluminum needs to be manually poured into the die either by hand or using a robot. Using hot chamber casting, the molten liquid zinc is shot into the die using a highly pressurized “plunger” which systematically shoots the zinc through the die.

 

Thinner Wall Stock

ZAMAK alloys have exceptional casting fluidity. It’s possible to cast walls in ZAMAK as thin as .25 inches. Thinner, stronger walls results in smaller and lighter products with lower costs.

 

Less Machining Required For Tight Tolerances

Zinc die casting has tighter tolerances than Aluminum or plastic die casting, which often eliminates the need for additional machining. When no additional machining is needed, it’s called “Zero Machining” manufacturing. This is one of the major advantages of Zinc die casting.

 

Superior for Decorative Finishing

ZAMAK alloys have a better surface for finishing because Zinc comes out of casting with a smoother skin. Because Aluminum has to be so much hotter than Zinc, the thermal shock from being put in a die produces a part with a surface that can be more pitted. Chrome finish amplifies every defect in a part, which makes Zinc much easier to finish compared to Aluminum. Zinc die casting parts can be easily polished, plated, painted, chromated or anodized.

 

Tough Durability

Zinc alloys are some of the strongest and toughest materials for die casting. Neither plastic, gray cast iron, nor Aluminum withstands impacts as well as Zinc alloys do.

 

If You Do Choose Aluminum

Sometime aluminum is the best choice. To learn more about aluminium die casting process or zinc alloy die casting, please visit Champion H&C Inc.

 

Champion H&C is expert of providing die casting parts and CNC machined products. If you need more information, feel free to send inquiry to let them know your requirements.

 

Article Source: http://www.brillcast.com/aluminum-die-casting.html

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Pro and Cons of Using a Malleable Iron Pipe

While malleable iron pipe fittings may sound old-fashioned next to lightweight PVC pipe, it has become valuable once more for solar heating systems, and other applications. Learn more about the pros and cons of malleable iron pipe below.

 

Pros of Malleable Iron Pipe

 

Malleable iron pipe fitting is the conduit system of choice for solar heating systems. Most solar heating systems for interior heat and hot water supplies use a dense fluid to trap solar energy. This fluid becomes much too hot for PVC pipes to tolerate, but malleable iron pipe is ideal to transport it. All the fittings of a solar heat system can be made of malleable iron pipe. Malleable iron pipe fitting is also best for cold water plumbing, as it retains its shape in the coldest conditions. Malleable iron is used for galvanized pipe fittings and can be zinc coated for rust and corrosion prevention prior to installation in a plumbing system.

 

Cons of Malleable Iron Pipe

 

Malleable iron pipe fitting without a galvanized zinc coating is unsuitable for factories and fluid transport facilities located near ocean and lake docks. It can rust and corrode on exposure to salt and other waterborne minerals. Heavy malleable iron pipe has been replaced by PVC for household plumbing.

 

If you need more information about malleable iron pipe fittings, visit the website of Golden Highope: www.golden-highope.com to find pipe fittings you need.

 

 

Article Source: https://www.doityourself.com/stry/pro-and-cons-of-using-a-malleable-iron-pipe

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Stainless Steel 430 Vs Stainless Steel 304

Stainless steel, a rust-resistant variation of ordinary steel, comes in many standard types, each identified by a number. Two, known as 430 and 304, have different properties that come from mixtures of iron and other metals in slightly different amounts. Both types have many practical industrial, medical and household applications.

 

Metals and Alloys

Stainless steel is an alloy, or combination of two or more metals, that has beneficial features not found in any of the metals by themselves. To make stainless steel, chromium is added to ordinary steel, giving it corrosion-resistant properties. Type stainless steel 430 is made up of 17 percent chromium and 0.12 percent carbon while stainless steel 304 contains 18 percent chromium and 0.08 percent carbon.

 

Magnetism, Cost and Physical Features

Raw iron is ferromagnetic, meaning you can attract it with a magnet, and you can make a magnet from it. The 430 grade stainless steel is also ferromagnetic. However, 304 is not. Type 430 steel is less expensive and is somewhat difficult to form and weld than type 304.

 

How They Are Used

Type stainless steel 430 is ideal for the production of automotive trim, the insides of clothes dryers and dishwashers. Manufacturers use stainless steel 304 in the production of kitchen sinks, counter tops, food processing equipment and other equipment regularly exposed to corrosive environments. Type 430 is one of the most popular grades of stainless steel.

 

If you have any interest in stainless steel 430 manufacturer, I recommend that you can visit the website of STANCH. The company can provide kinds of stainless steel products including stainless steel coils, stainless steel strips, stainless steel plates and more. More details, please visit STANCH Stainless Steel Co., Ltd.: www.stanch.com

 

 

Article Source: https://sciencing.com/430-vs-304-stainless-steel-7744463.html

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