Mercert

If you are a forging enthusiast or an entrepreneur who wishes to grow in that path, you have to understand and know a couple of things. Different processes apply to any cold forging, the type of product you will want to come up with. For instance, you might want to learn how best or what process is best for making cold-forged steel. Read through this article to know the best and common processes that are popular among cold forgers.

Cold Rolling

In this process, you pass the metal through rollers that are constantly rotating. The rotation of these roller cause deformations by the use of comprehensive force. The friction produced between the rolls and the metal stock surface is due to the comprehensive stresses or forces. Steel metal is best for this process and is preferred so much by artisans.

Closed Die

In this process, you are required to use mechanical blows to shape a workpiece. This is done after placing the workpiece between two die halves. Use the hammer to strike the workpiece multiple times, just like the drop forging. The striking causes the metal to flow into the cavities of the die. This enables a smooth change of the shape of the metal.

Drawing

The drawing process requires you to pull a workpiece through a die. You might need to use a tensile string at the exit of the die. As you pull the workpiece, you are constantly reducing the cross-sectional area while increasing the length of the workpiece. You will have achieved close dimensional tolerance as compared to using the rolling process.

Extrusion Process

In this process, you will have to force a billet through a die. With the aid of the comprehensive force below, you will cut the final piece to the required length. The cut pieces are sent further processed using about 20,000kN of force to achieve the desired piece.

Open Die

This process uses two flat dies that don’t have a profile that is pre-cut. There are several processes that you will use progressively to shape and size your final piece. This process is best if your pieces are significant components of metals. Metal components that are heavy and big require a lot of integrity in structuring, making this process the best for this purpose.

Ring Forging

As the name suggests, you will need to use a doughnut-shaped circular workpiece. You will need to hammer and squeeze the piece while rotating it. Through this process, you will produce seamless rings and have diameters and strengths that are perfect.

Swaging Processes

This is also referred to as radial forging. In this process, you deform two parts of the workpiece to ensure the fit to each perfectly. You can highly rely on the process as it is automated. There are two types of swaging that you should be aware of; radial and tube swaging.

Bending process

Last but not least bending process is one where you press a workpiece through a shaping tool. Also known as pyramid rolling, it is used as an initial process for another cold forging process.

Flexible printed circuit boards (PCBs) are perhaps the most ideal solutions for all commercial electronics needs. Basically, a flexible PCB is a printed PCB that can flex freely. Because of this, they arise from different types with various features most particularly in manufacturing, design, and functionality.

Flexible PCB boards have been primarily used for several applications such as computer networking, industrial automation, medical equipment, telecommunications, and even the aircraft and transportation industry. In addition, several innovative technologies such as touch screen technology and electronic document scanning have also been applied to these boards. Because of its flexible nature, PCB manufacturers have been able to create different varieties such as full flex and half flex PCBs.

Half flex PCB is typically used in multi-board applications such as electronic data cards, flat sheets of memory chips, and communications systems whereas full-flex PCBs are widely used in high-volume audio and video applications and in several other industries. Besides, flexible printed circuit boards have also been successfully utilized in several different sectors such as chemicals, water purification, electricity, automotive, military, aerospace, and many others.

Easy-to-Install & Lightweight Flexible PCBs

The advantages of using flexible PCB in various applications are numerous. In particular, these flexible PCBs are capable of fitting into a different space required for various applications. For instance, they do not require any extra space for installation purposes and can be installed easily on the edges of different devices.

Another advantage of the flex circuit board is its lightweight feature, which makes it perfect for mobile applications. Moreover, these flexible printed circuit boards have also been found out to be quite effective in eliminating the risk of short-circuiting which is one of the most common failures observed in electronic components. In addition to this, they also offer greater flexibility in addressing fluctuating environments by offering the capability to change their position and connection directions when required.

Large Storage Capacity of Flexible PCBs

There are a number of advantages of using flexible printed circuit boards. As mentioned above, these types of boards have a larger storage capacity as compared to their fixed counterparts. Also, the smaller size of the flexible PCB allows for easy removal and modification without requiring the assistance of technical personnel. This allows for simple roll-off packaging and efficient shipping, which are vital for e-Commerce. Another advantage of flexible PCBs is that they are suitable for use in a wider range of electronic equipment and devices because of their ease of use.

Durability & Flexibility of Flexible PCBs

In general, there are many advantages associated with using a flexible printed circuit board. Due to the greater durability and flexibility, the reduction in defects and the increase in productivity have been seen as many benefits by manufacturers. Apart from this, the manufacturers have also seen the usage of such PCB in the healthcare industry. The PCBs used in this case is commonly used for medical applications because they are considerably more durable than the traditional rigid PCBs and offer a higher level of performance at a lower cost.

Alnico magnets are permanents magnets made from combining Aluminum (Al), Nickel (Ni), and Cobalt (Co). Sometimes, they also contain Titanium and Copper. These magnets feature a powerful magnetization element. Alnico magnets come in various types, sizes, and shapes, depending on their manufacturing method. This post looks at the casting method of manufacturing Alnico magnets.

How are Alnico magnets manufactured?

The manufacture of Alnico magnets involves a series of in-depth processes. The first thing that happens during the manufacture of Alnico magnets is selecting the element combinations. Note that the specific combination of essential Alnico components is determined by the intended type of Alnico magnet and its applications. Once the combinations of the elements are determined, the manufacturing begins. Note that there are various methods of Alnico magnet manufacturing. The most common one is the casting method. Below are processes involved in the casting method of Alnico magnet manufacturing;

1. Heating

Here, the correct amount of Alnico elements are placed in a furnace. They are then melted at around 1750 degrees Celsius. One of the primary elements used is Aluminum. Note that some of the Aluminum tends to melt away. Therefore, in some cases, you may have to add some extra Aluminum to replace the one that melts away. The best manufacturers usually cool a sample of the elements for inspection before going to the next step.

2. Casting

Once the elements have been heated and transformed into molten form, they are poured into a green sand mold. The mold is usually designed to be large enough to allow shrinkage as the elements cool down. Once the molten elements have cooled down, the mold shell disintegrates, leaving a slight residue. The casting process allows for the manufacture of various shapes of Alnico magnets, including complex shapes. It is worth mentioning that unique machining methods are usually applied in this stage as Alnico magnets are prone to cracking and chipping.

3. Felting

After the casting process, the cooled magnets are removed from the mold. They are then felted on a grinding wheel. The role of the felting process is to clean out the cooled magnets and remove any remaining mold runners.

4. Heat treatment and hardening

The next step of the process is heating the magnets and placing them inside a magnetizer. The magnets also have to go through the hardening process. This is where they are exposed to a powerful magnetic field as they cool down. Afterward, they are placed in an oven where the magnetic field is tempered and stabilized. This is done to provide the magnet with its final magnetic properties.

5. Grinding

The magnets are ground one last time. The role of this step is to ensure that the magnets achieve their dimensional and surface finish tolerance requirements.

6. Testing and coating

The manufactured magnets are tested using hysteresis graph testing. This test inspects the quality and design, among other characteristics of the magnet. Finally, a protective coating is added on the Alnico magnets to ensure their durability and enhance their appearance. More often than not, the poles are left unpainted.

Conclusion

After the testing and coating process, the magnets must be magnetized. Here, they are placed in a coil or a solenoid. An electrical pulse is used for the final magnetization process. Since alnico magnets are permanent magnets, they do not lose their magnetic strength after the final magnetization.

The market features a wide range of 3D printer manufacturers. JGMakers is one of the leading manufacturers in this category. The company is known for manufacturing a wide range of 3D printers, printing materials, and accessories. Click here to read more about JG Makers and what they have to offer. This post looks into 3D printed product qualities and elements that impact them.

Factors affecting the quality of 3D printed parts

3D printed parts are known for their high quality. 3D printed parts are usually highly precise, strong, highly durable, and come in varying shapes and complexities. However, the quality can be affected by the following elements:

1. Printing material

The material used in 3D printing is known as filament. The market features a wide range of filament types. The filament can be made from various types of plastic, metal, and sand. Each type of filament features different qualities, advantages, and shortcomings. Naturally, the higher the quality of the filament, the higher the quality of the printed products. For instance, products made from strong printing materials turn out highly solid and durable. On the other hand, products made from inferior printing materials or filaments tend to feature inferior quality. For this reason, one of the primary factors that affect the quality of 3D printed products is the printing material.

2. Type of 3D printer

The market features a wide range of 3D printer types. Some of the most popular ones are FDM, SLA, SLS, and SLM 3D printers. Each of these printers uses varying 3D printing technologies. They all work differently, and they have their shortcomings and advantages. Some types of 3D printers produce better quality 3D printed products than the rest. This is because of how the 3D printers work, their components, and the type of printing materials they accept. Simple elements like the thickness of the layers extruded by the printer can influence the quality of the surface. Therefore, the type of printer used for the printing process will significantly influence the quality of the 3D printed products.

3. The quality of the CAD model

The CAD model is also known as the blueprint. It is usually created in the first step of 3D printing then translated and fed to the printer. The CAD model is made from the original product design made by the creator, inventors, or manufacturer. Note that the entire 3D printing process is usually automatic. This means that it does not require human input. The only part of the process is that requires some human input is making the CAD model. However, a type of software is also applied. Therefore, if there are any issues with the CAD model, they will show in the final product. This is why the CAD model will affect the quality of the 3D printed product.

Conclusion

In addition to the features above, the way the 3D printing process is conducted will affect the quality of the products. This is the reason why companies hire 3D printing companies to take care of their manufacturing needs. Regardless, 3D printed parts are very reputable because of their quality. They are strong and can last for a long time.

The medical industry is among the sectors that use the prototyped parts in its operations. The technology has advanced tremendously such that parts such as pacemakers can be developed. The growth in the medical industry has reduced the chances of death significantly. Also, parts such as hip replacements protect patients from using wheelchairs all their lives. Companies in the prototype manufacturing industry have been a lifesaver for most. Prototyping is found in many countries like prototyping china. This post aims at updating you on the Application of the prototyping process in the medical industry.

Examples of prototyped medical parts

• X-ray equipment
• MRI devices
• Ultrasonic equipment
• Medical monitor devices

Application of the prototyping process in the medical industry

There are four critical steps in developing medical devices

1. Alpha prototypes

The first step in developing medical devices prototypes is the Alpha prototypes. At this step, the manufacturer utilizes a 3D printer to check out the medical prototype dimension. There is no actual production at this step. Therefore, you get to save time and money on the purchase of material and production services. The 3D printed medical prototypes are used to check whether every angle is done correctly and how it will appear once production commences. The 3D-printed medical prototypes at this step are non-functional.

2. Beta prototypes

The second step involves the beta prototypes. The manufacturing method used at this stage is more refined. The main goal of this step is to check out whether there are any issues with the manufacturing processes and the design’s functionality. Compared to the alpha prototypes, the medical device prototype is functional at this stage, although its exterior design may not be the same as the expected output. Also, the prototypes used at this step can be used to seek out investors.

3. Pilot prototypes

The third step in the medical prototype developing process is the pilot prototype. The pilot prototype design is almost identical to the previous step, but it looks more like the final output. The medical prototypes manufactured at this step are mainly used for clinical trials and device launches. The prototype manufactured follows the precise material and design specifications.

4. Final product

The last step involves the production of the final product. This step ensures that the design is fully functional. In addition, it incorporates the previous steps and any modifications made to the design. This final step produces the final medical prototyped device.

Machining methods used to produce the medical prototyped device

• Vacuum Casting: This technique is best suitable for flexible and rigid parts. This method is very affordable, and it ensures that the surface finishing is very smooth.
• Aluminum machining: This technique allows manufacturing companies to develop products and prototypes of very high quality.
• Clear acrylic polishing and machining: This technique is used for products such as lenses. It ensures that the parts are created with high levels of precision and quality.
• CNC machining: This technique allows for the production of medical devices that requires a tight tolerance.

Conclusion

The medical industry cannot function as properly without the prototype development processes. Some of the equipment, such as the MRI equipment, is essential for running tests. The existence of prototyping allows for services in the medical field that would not have otherwise existed.

The industry of CNC machining China is broad. There is a wide range of companies in China providing a wide range of CNC machining services. A lot of companies outsource their CNC machining services to China because of the affordability of the services. Chinese CNC machining companies are also highly experienced. They have worked with hundreds of companies, hence have acquired a lot of experience in this sector. Therefore, you can trust these companies to provide the best services and use top-notch equipment. In this writeup, we discuss CNC machined parts. 

Types of CNC machined parts

CNC machining can be applied in a wide range of parts. Below are some popular CNC machined parts:

1. Complex surface parts

CNC machining is used to manufacture complex surface parts in the aviation, design, and transportation industry. Here, parts like cam, integral impeller of aviation, propeller, and die cavity. These parts consist of complex curves and curvy surface outlines. These elements cannot be achieved using ordinary manufacturing techniques. For this reason, CNC machining is applied. CNC machining offers a high level of processing accuracy. This is done using precision casting. The use of multi-axis CNC machining machines also helps with precision and manufacturing accuracy.

Additionally, the automatic programming technology used in CNC machining helps significantly improve the production efficiency and complexity of complex surface parts.

2. Special-shaped parts

The term “special-shaped parts” refers to parts with irregular shapes. These parts require multiple stations and mixed processing points. They also feature mixed processing lines and surfaces. Examples of such materials are brackets, base, and die relief. When manufacturing materials with unique shapes, higher precision is required. This is where CNC machining comes in. In CNC machining, technology and multiple axes are used to ensure higher accuracy. Several other types of manufacturing techniques cannot achieve this level of accuracy.

3. Parts with complex structures

Various industries like the robotic, automobile, and aircraft, to name a few, is where parts with complex structures are applied. These are parts with higher degree requirements, large size, and intricacies. Most manufacturing techniques would take a lot of time and effort to achieve the complexity of these structures.

However, in CNC machining, more than 70 percent of the manufacturing process for complex structures can be completed by a single clamp. However, this highly depends on the type of CNC machining service applied. CNC machining services with high processing efficiency, proper stiffness, and automatic tool changing capabilities are always a better option for making parts with complex structures.

4. Prototype parts

Prototypes are draft parts used in the trial production phase for new products. CNC machining is used for making prototypes because it is a fast technique. CNC machining techniques can be applied in rapid prototyping. In CNC machining, when the CAD models are designed, the details are stored in the software. This makes it easy to make changes to the design after the trial phase and produce another prototype, as is the case in rapid prototyping.

Conclusion

CNC machining is highly applicable in a wide range of industries. Whether it is complex structured, large, or intricate parts, you can count on CNC machining producing high-quality outcomes.

CNC machining involves the cutting technology where materials are removed from an object. It is a subtractive process commonly used for low volume and rapid prototype manufacturing. Computer Numerical Control or CNC means that computers control the different machining parts and cutting tools during manufacturing. In this extract, we look at types of CNC machines.

Types of Machines Used in CNC Machining

Machining is important in many applications. The manufacturing industries use a variety of machines, each serving a different purpose for product production. Some common CNC machines are;

1. CNC Milling Machines

These types of machines are the most popular in the manufacturing setup. CNC milling is, therefore, a common operation that relies on cutting tools that rotate around a workpiece to create a specific shape. The milling machines use computers to facilitate this process. This works because the computers are fed with numerical codes that pass instructions to the simple mills on how to proceed with the machining.

2. CNC Router Machine

This CNC machine is so called the router machine due to the routers found on it. The router machine is prevalent in the market due to its ease of use. Operating it is a straightforward thing hence anyone can run it efficiently, be it a first-time operator or a regular user. This element sets apart these machines from the rest since it is specifically designed to carry out CNC operations, and human involvement is limited.

The CNC router machine has several characteristics that make it possible to use in various applications. It has an in-built design that produces larger dimensions of objects than other machines. These features enable it to cut materials like wood and sheet metal into the desired shapes. In addition, the CNC machine has a rotary located on the workpiece and routers positioned in three axes, i.e., the X, Y, and Z axes. This means it is designed for machining flat parts, but some manufacturers use it on 3D objects.

3. CNC Plasma Cutter Machines

These types of CNC machines are mostly used in heavy-duty applications to cut heavy materials. Several materials are used in the manufacturing process, like metals, and the most common is steel. The machines work by cutting the material on a workpiece or object using a plasma torch.

4. CNC Lathes Machines

Generally, manufacturers use lathes to create conical and precise parts. The lathe machine is primarily used to turn centers or cut off excess material during the cutting process. Like the CNC router machine, it is easy to operate, fast and accurate. It comes in different forms based on varying qualities and is used in many industrial applications.

5. CNC Electric Discharge Machines

EDMs are used to produce shapes from a workpiece. The machine employs electrical release in parts production where the material is cut from the object. During the process, two existing anodes are separated by a dielectric liquid. One disadvantage of this machine is using it isn’t easy compared to others hence they are not very popular.

Conclusion

The examples above are the main CNC machines available in the market. They are all essential in the manufacturing industry but have different characteristics that make them different, like the materials they use, the parts they manufacture, and how they work.

Marketing and selling finished products require some finesse and skill. However, one of the very obvious facts every producer and marketer knows, is that lack of good packaging can significantly reduce attraction and customers’ inclination to buy a product.

Thanks to technology, with the use of an automatic packaging machine, it is possible for every manufacturer to have beautiful packaging. An automatic packaging machine increases speed in the final stage of production and enhances the aesthetics of your product. Read on to find out further advantages of purchasing an automatic packaging machine.

Benefits of Automatic Packaging Machine

There are numerous benefits of packaging

1. Increases volume of sales

With good packaging, the consumer is easily attracted to the finishing. It is this attraction that causes them to inquire about the content. Good packaging makes it easier to close sales and hit sales targets.

2. Authenticity

Good packaging increases the authenticity of your product. Many people have the notion that if it is packaged properly, it is most likely a quality product. While this is not always true, it is often true. So, packaging your goods properly will buy the trust of consumers easily.

3. Smart Investment

An automatic packaging machine is a smart investment for your business because it is a one-time purchase. Like all machines, what it needs is routine maintenance and a clear understanding of how to operate it.

With an investment like this and proper maintenance, all that will be needed are operating managers and this machine can be used infinitely as long as maintenance is religiously adhered to.

4. Branding

The goal of product manufacturing is not only to have consumers but to have constant consumers. Using good packaging by using an automatic packaging machine will ensure that your product has a signature look. This will make it easy to retain consumers.

5. Reduces cost of production

An automatic packaging machine cuts back on manual labor which is a good thing for the businessman. It gets the packaging job done more efficiently and speedily and removes the element of fatigue because a machine is not human.

This means that you can easily set time frames for production and be sure that it will not be delayed by tired hands, unforeseen ailments, and the many other complications that can arise with human resources.

6. Prolongs Product Life Span

This is highly dependent on the type of product you sell. For food products and other products that require preservation, inadequate packaging can lead to a short life span of that goods.

The danger with this is, the goods may not go bad while in your care, but they can go bad just before the final consumer gets it. It can cause ailment which can lead to lawsuits for your company, loss of income, and loss of consumer trust. But all these can be avoided with the right equipment, which is an automatic packaging machine.

7. Protection

The process of goods transportation is often rough and hardly gentle. With good packaging, your product will be protected from damage and you can be assured that no matter the time frame the logistics demands, your goods will get to the final consumer, it will be gotten in a good, working condition.

Conclusion

Having an automatic packaging machine is a good investment for your business. All you need to do is to decide on the type of packaging you want and purchase one that suits your product.

Surface finishing is a term used to describe the different types of manufacturing that work to improve the overall beauty and appearance, strength, and a host of other properties that make a finished product. One of these manufacturing processes is prototype manufacturing. They add, alter, remove, and reshape the material of a given product, and they are often achieved through the application of mechanics, chemicals, and electrics.

In all, sanding and polishing are part of the most popular ways to achieve a clean surface finish. Do you want to find out more about surface finishing, and all there is to it? Then keep scrolling:

Processes of Surface Finishing

While there are lots of processes used for surface finishing, here are the most common ones in the industry:

1. Sanding

This is easily considered the most popular process of surface finishing. It’s the process of getting rid of the surface material using a disk or an abrasive sheet. It’s recommended that you use the fovitic sanding method. That’s because it enables you to get past some general problems associated with sanding.

2. Polishing

Similar to sanding, polishing uses a finer means of abrasion to finish a surface. However, if you’re using robots to polish, you may encounter different factors that can affect its quality. These factors include; wear rate, connection to robot, the strategy used, etc.

3. Sand Blasting

Sandblasting is achieved by driving the abrasive beads onto the desired surface. This helps to rapidly remove the material.

4. Electro polishing

This is a surface polishing process that involves the use of chemicals instead of mechanical procedures to polish. Electro Polishing is often used to remove the surface of stainless steel.

5. Passivation

The common agents used during passivation are nitric or citric acid. They help to remove free iron on the surface of the steel to improve its resistance to rust.

6. Electroplating

This process uses electricity to coat one metal alongside a bonded thin layer of a different metal.

Must Surface Finishing Always Involve Manual Operation?

A lot of processes used for surface finishing require that you use manual operation. But for some such as polishing, sanding, or buffing, you can perform them using a robot.

How Does Surface Finishing Work?

When performing a surface finish, the end goal is usually to improve a product’s appearance, chemical or mechanical properties. Depending on the process you’re using, you can achieve surface finishing in different ways. Nonetheless, they can be divided into four categories. You can either:

• Add Materials -this is a process of including extra material on the product’s surface. It can be done through galvanizing, powder coating, or plasma spraying.
• Alter Materials- Pickling, carburization, or flame polishing are the different ways that you can alter the chemical or material properties of a product.
• Remove Materials- This is done through the use of chemicals or abrasive media.
• Reshape Materials – Here, chemical pressure is added to define the surface of the material.

Final Thoughts

Before performing surface finish on your product, you should understand what the process entails. This guide shows you exactly how surface finishing works.

A flexo printing plate is a light-sensitive plate (photopolymer) used to transfer ink to a substrate during printing. There are different ways of processing these plates: digital, traditional, and thermal flexo plate processing. Note, the plates’ specifications vary depending on the process used, but one thing that should remain constant is the methods to maintain them. In this extract, we discuss the tips for maintaining a flexo printing plate.

Tips for Maintaining a Flexo Printing Plate

1.Relief Depth

A plate has two sides, the bottom side, the floor of the plate, and the upper side, also known as the printing surface. This is the side that the prints appear. The difference between the two sides is what is known as the relief depth. The depth varies with each plate depending on the thickness. Each plate thickness has a recommended depth that should get considered for you to produce a high-quality plate.

2. Quality of Image

The original image plays a significant part in determining the quality of the flexo plate. Whether the processing machine uses a digital or traditional plate, the final product will match the original one. If the quality is poor, the end product will also be of low quality and vice versa. When using film to develop traditional plates, the film density must be kept over 4.0. The digital plates, the imager should get checked to ensure the focus and settings are okay. Lastly, the test should be done periodically and, most importantly, done by an expert.

3. Drying Process

Using flexographic plates before they are completely dry shortens their life span and leads to poor registration. The plate is an essential part of the printing process as it transfers ink to the printing material. A wet plate appears swollen due to solvent retention. Certain factors may cause a plate not to dry completely, such as poor air circulation in the dryer or removing the plate from the dryer earlier than intended.

4. Conditions of Exposure

The printing room should be kept clean, free from dust and dirt. These slowly damage the plates, reducing their life. Also, the plate has two UV bulbs that need to be checked regularly and also replaced. Weak bulbs may extend the exposure time but lead to widened plate shoulder angles, damaging the flexo plates.

5. Saturation of the Polymer

The plate making solvents use water or hydrocarbon solvent to wash away excess polymer found in the plates non-printing areas. During this process, the polymer solids are contaminated, and how saturated they determine the plate’s quality. The concentration of the solids should be kept below 6%. The machines should also be cleaned often to remove all-polymer particles that may build up over time.

6.Plate Handling

The plates are delicate and fragile; hence should be handled with care. A plate should not be folded, placed on sharp objects, exposed to harsh chemicals or direct sunlight.

Conclusion

The factors discussed above are essential and should be considered when maintaining the plate’s quality. Remember, when plates are well maintained, your printing quality will always be top class, and lastly, the very plates will last long.