Identify Raw Materials and Sources What raw materials will have the characteristics necessary to meet the requirements of your parts?
How will your requirements be achieved? Document the Quality Control System Your provider should document the components of their quality control system in writing, including the processes to be used, general procedures, and any other factors that can have an impact on quality. How will accuracy be maintained? Calibration, Standardization, and Tolerancing The devices that will be used to measure the dimensions of finished parts must be calibrated according to accepted standards , such as NIST, and validated that they will provide the accuracy you need.
How will results be verified? Initial and In-Process Inspections In addition to inspecting all incoming materials before product begins, your parts provider should establish inspection points along the manufacturing process, to maintain acceptable part quality and spot any variations before they have an impact on quality.
Regular inspections allow a manufacturer to: Identify when the upper or lower limit of the tolerance range is approached Change the tool to bring the measurement back to nominal and keep the parts within the acceptable tolerance range The movement away from nominal is steady and somewhat predictable, allowing in-process checkpoints to be set.
Per ISO , here at Metal Cutting we have a system in place to: Quickly remove nonconforming material or parts from the production line Maintain traceability throughout the manufacturing process It is important to remember that random things can occur during manufacturing that might cause a nonconforming part to slip past a sample inspection checkpoint.
The plan typically includes: How to inspect the finished parts, including which dimensions of the parts will be examined When inspections will take place, including in-process checkpoints and final inspection The AQL and index values that determine how many randomly selected parts in each lot will be inspected We generally use AQL 1. Conclusion: What completes a quality package? Tungsten Uses Then and Now In comparing common tungsten uses in and today, it is clear that tungsten remains one of the most widely used and beneficial of the refractory metals.
Other Content in this Stream. Why Copper Tungsten? Manufacturability Learn how the properties of copper tungsten reduce or eliminate the challenges posed by those materials when they are used in their pure forms.
The Right Electrode Material for Your Resistance Welding Application Learn why resistance welding electrodes require a material with the right combination of thermal conduction, electrical resistivity, and reactivity. Optimizing the Life of Resistance Welding Electrodes Learn how best practices as well as material and design considerations have an impact on the life and effectiveness of resistance spot welding electrodes.
Choosing the Right Resistance Welding Electrodes for Hybrid Vehicle Battery Packs When choosing a resistance welding electrode for any application, a thorough understanding of material properties helps to avoid production line issues. Resistance Spot Welding Electrodes: Understanding the Variables Learn about the variables to consider when choosing the best resistance welding electrode material for specific resistance spot welding applications. Electrode Properties in Resistance Spot Welding: Why They Matter Choosing the right resistance spot welding electrode for an application depends on understanding critical properties of the different electrode materials.
Resistance Welding Electrodes for Your Application Get answers to common questions about dissimilar metals regarding high and low conductivity electrodes and friction stir in the construction of an electrode. The Allure of Laser Cutting While laser cutting can produce a small kerf and tight tolerances, other precision cutting methods may be preferable for 2-axis cutoff of small metal parts. Key Parameters for Choosing a 2-Axis Precision Cutting Method Learn the key parameters for choosing a method of 2-axis precision cut off of metal parts based on part type, material type, and part dimensions.
Your Tight Tolerance Could Be Seriously Affecting Part Cost Learn about the role that tight tolerance plays in optimizing for manufacturability, and how to specify tolerances to ensure part quality and control costs. Avoiding the Risks of Standard to Metric Tolerance Chart Conversion With a metric tolerance chart, you need to account for the upper and lower tolerance spec limits when converting between standard and metric measurements. A Case Study in Precision Cutoff vs.
Stamping Learn how precision cut off and stamping compare in achieving distortion-free flatness, a sharp edge, and the precise exterior diameter needed for a spacing ring. How to Avoid the Issues of Non-Standard Material Size In material sourcing for the production of precision parts, avoiding non-standard material sizes can help to control costs and optimize for manufacturability.
The Inside Dope on Dopants and Wire Recrystallization Dopants raise the recrystallization temperature of tungsten wire and other wires, giving non-sag properties to tungsten light bulb filaments and other products. How to Utilize Tungsten in an Automotive Application Learn the advantages of copper tungsten electrodes for resistance spot welding of wire harnesses in battery electric vehicles BEVs.
Utilizing Tungsten Wire in Medical Device Applications The properties of tungsten wire are valued in the medical device industry, for use in electrocautery, electrosurgery, neural probes, and other applications. Utilizing Tungsten Wire in Applications for General Industry With its unique properties, tungsten wire is used in a wide range of industry applications, from tungsten filament wire bulbs to tungsten thermocouples.
A Closer Look at Utilizing Tungsten Wire for Probes The straightness properties of tungsten wire make it valuable for small diameter tungsten probes used in semiconductor wafer testing and neural activity testing. Top Applications for Gold-Plated Tungsten Wire Gold-plated tungsten wire is useful in filtration, printing, copying, and other applications, and as an alternative to precious metals in some medical devices.
Resistance Spot Welding Is Still Spot On Take a look at how resistance spot welding compares with laser, ultrasonic, and other newer welding methods. Choosing the Right Material for Spot Welding Electrodes Explore the advantages of pure tungsten and pure molybdenum as alternative materials for use in spot welding electrodes.
A Recipe for Perfect Electrode Infiltration Learn why infiltration, density, and other properties of an alloy such as copper tungsten are important to the quality of spot welding electrodes. The Cure for Some Common Electrode Bonding Problems Learn how the right electrode material, design, and construction can help to prevent bonding problems in resistance spot welding electrodes. Problems with the Glass to Metal Seal in Electronics Learn how to prevent and detect surface flaws in the glass to metal seals used in the manufacture of a wide range of electronic products.
Sealing the Package: Potting and the Flat Ribbon in Switches and Relays Learn how potting can be used to create a tightly sealed package for electronic switching devices, such as the flat ribbon in semiconductors.
Utilizing a Vacuum Atmosphere in Electronic Device Manufacturing The process of creating a vacuum atmosphere, either repeatedly or in one-time production, is an important part of electronic component manufacturing.
The Role of Precision Tubing in Liquid Dispensing Systems: Part 1 Precision tubing plays a vital role in helping to ensure the accuracy of liquid dispensing systems used in many biotechnology and laboratory environments.
The Role of Precision Tubing in Liquid Dispensing Systems: Part 2 of 3 The characteristics of the precision tubing used in liquid dispensing systems can significantly affect the fluid dispensing process and testing accuracy. The Role of Precision Tubing in Liquid Dispensing Systems: Part 3 of 3 See which tubing characteristics matter in high-pressure applications for liquid dispensing systems.
Precision Metal Tubing for Automotive Safety Systems Precision metal tubing plays an important role in the airbags that are part of automotive safety systems. Tungsten Wire Refuses to Die in Automotive Lighting Incandescent bulbs made with tungsten wire filaments continue to be used in automobile turn signals despite the parallel adoption of newer LED technology. Choosing a Vendor for Cut Off Metal Parts Follow these tips on how to choose a vendor for cut off metal parts and get the results you want for your precision manufacturing needs.
Small Gages in Metal Parts Sourcing Small gages such as pin gages or pin plug gages are useful tools for inspecting IDs and making sure small diameter metal tubing meets specified tolerances.
Heat Expansion of Metals and the Summertime Blues Utilizing a controlled environment helps to minimize the effects of heat expansion and other temperature issues on the measurement of metal parts. Dimensional Issues in Metal Cut to Length Metal Cutting utilizes lapping and machining as well as other techniques to achieve flatness vs. The Technology of Autonomous Vehicles Take a closer look at the technology behind autonomous vehicles and the implications both on the road and off.
Top 5 Challenges in CNC Machining Explained Learn about the five major challenges to consider when choosing CNC machining services and a partner for the manufacture of complex and precise small parts. Barriers to Lights Out Operation in Precision Machining While automation plays a growing role in precision machining, lights out operation is still more a fantasy than a reality for most small part manufacturing. Metal Finishing to Prevent Corrosion of Precision Parts Find out if metal passivation is the right finishing option for your precision small metal parts or other application.
Deburring in Mass Production of Small Metal Parts For deburring of small metal parts, mass production requires the action of hand tools to be re-created by mechanical devices suited to high-volume applications. Why Use a Surface Finish Chart? Specialty Metals for Medical Device Applications The creation of new specialty metals offers alternatives to stainless steel for components used in medical device applications.
Principles of Precision Surface Grinding Services Surface grinding services utilize precision surface grinding methods to make cubic metal parts square and parallel or the ends of metal rods perpendicular. Circularity Tolerance in Small Metal Parts Circularity tolerance based on diameter helps to control roundness and ensure that small precision metal parts fit properly, move smoothly, and wear evenly.
The Sampling Plan in Quality Control A statistically valid sampling plan in quality control provides a high level of confidence that if the sample is acceptable, the entire lot is acceptable. A Comparison of Honing and Lapping While honing and lapping are both used to fine-tune the finish and dimensions of metal parts, the two processes differ in where and how they achieve results.
Circular Runout vs. Total Runout In circular runout vs. The Quandaries of Calibration Standards Calibration standards for devices and equipment used in measuring, inspecting, and manufacturing of precision metal parts can pose some unique challenges. Happy Birthday to Metal Cutting Corporation! What Is Calibration Tolerance? Wire EDM Cutting Pros and Cons Wire EDM cutting advantages and disadvantages for 2-axis cutoff depend on factors including the material used, part parameters, and surface finish requirements.
Better Together: Non Defective Bonding of Resistance Spot Welding Electrodes Proper electrode design and construction is essential to ensuring consistent weld quality, minimum electrode sticking, and maximum electrode life. Tungsten Wire Overview of a Uniquely Useful Material Tungsten wire continues to be a product that has a large number of diverse applications, for many of which there is no known substitute.
Tungsten vs Gold: Choosing a Biomedical Alternative Learn how tungsten as an alternative to precious metals can help you achieve uncompromising quality and still keep your budget on track. Copper Tungsten Alloy: The Top of Mind Electrode Material for EDMing Carbides For intricate geometries, sharp corners, unparalleled wear resistance, excellent cutting speeds and machinability, copper tungsten is the material of choice.
Seven Secrets to Choosing A New Contract Partner Finding a supplier who can deliver quality and on-time service can be tough, especially when it comes to the medical device and other heavily regulated industries. Metal Tubing in the 21st Century: Who Needs it?
Resistance Welding Electrode Materials: A White Paper Learn how better materials for resistance welding electrodes speed up your welding operation. Do you know which cutting method is right for your precision application? Notice: JavaScript is required for this content. Precision Metal Cutting for 2-Axis Cutoff Different precision metal cutting options vary in characteristics and appropriate applications, making the choice not quite so easy.
Fundamentals of Centerless Grinding [VIDEO] The centerless grinding process is ideal for finishing small cylindrical metal parts that require a tight tolerance and high-volume production. The Complexities of Electrochemical Grinding The electrochemical grinding process is a highly specialized method that combines surface grinding, chemistry, and fixturing, and has limited applications. Fundamentals of OD Grinding OD grinding is used to shape the external surface of objects between the centers and excels at removing circular defects and restoring or creating roundness.
Applications for Precision Flat Lapping Services Precision flat lapping and other lapping techniques can be used for small parts requiring tight control of surface finish, flatness, thickness, and parallelism. Fundamentals of Double Disk Grinding Double disk grinding provides dimensional accuracy for metal part applications that require tight tolerances, parallelism, flatness, and thickness control.
Specialized Methods of Internal Grinding High precision internal grinding methods such as ID grinding and honing are used to achieve smooth finishes and tight tolerances on bore, hole, and tube IDs. Precision Metal Grinding Precision metal grinding is often the best way to remove small amounts of material and achieve the right finish or tight tolerance dimensions on part surfaces. Quality Control in the Manufacture of Metal Parts Learn the vital components of an effective quality control program and its role in ensuring that metal parts meet their requirements for design and function.
Milling machines of non-conventional design have been developed to suit special purposes. This machine has a spindle for rotating the cutter and provision for moving the tool or the work in different directions.
The following special types of machines of interest are described below:. Here the table is circular in nature and rotates about a vertical axis. Here cutters are set at different heights. Which results in one cutter roughing the workpiece and other one cutter finishing them. The advantage of this machine is that continuous loading and unloading of workpieces can be done by the operator, while is in progress. It is like a rotary table milling machine.
The face milling cutters mounted on three or four-spindle heads rotate in a horizontal axis and remove metal from workpieces supported on both the faces of the drum. The finished machined parts are removed after one complete turn of the drum, and then the new ones are clamped to it. Here workpiece is held stationary while the revolving cutter. The cutter moves in a travelling path to finish a cylindrical surface on the workpiece either internally or externally.
This machine is also adapted for milling internal and external threads. A pantograph machine can duplicate a job by using a pantograph mechanism. It allows the size of the workpiece reproduced to be smaller than, equal to or greater than the size of a template. Also used for the different model for special purposes. A pantograph is a mechanism that is generally constructed of four bars or links which are connected in the form of a parallelogram.
Pantograph machines are available in two dimensional and three-dimensional models. The two-dimensional pantograph is used for engraving letters or other designs.
Whereas three-dimensional models are employed for copying any shape and contour of the workpiece. A profiling machine duplicated the full size of the template attached to the machine.
Here the spindle can be adjusted vertically and the cutter horizontally across the table. A hardened guide pin regulates the movement of the cutter. The longitudinal movement of the table and the crosswise movement of the cutter head follows the movement of the guide pin on the template. The tracer controlled milling machine reproduces irregular or complex shapes of dies, moulds by synchronized matched movements of the cutter and tracing elements.
The movement of the stylus energized an oil relay system which in turn operates the main hydraulic system for the table. This arrangement is termed as a servomechanism. A milling machine is a machine tool that cuts metal as the workpiece is fed against a rotating multipoint cutter. The milling cutter rotates at a very high speed because of the multiple cutting edges, it cuts the metal at a very fast rate. This machine can also hold single or multiple cutters at the same time.
A solid cutter has teeth with the cutter body. The cutters are of smaller diameter and made of one piece material usually of HSS high-speed steel. A tipped solid cutter is similar to a solid cutter, except that the cutter teeth are made of cemented carbide or stellite tips which are brazed on the tool shanks of an ordinary tool steel cutter body to lower the cost of the cutter.
In large milling cutters, the teeth or blades are inserted or secured in a body of less expensive materials. The blades are held in the cutter body by mechanical means. This arrangement reduces the cost of the cutter and enables economy in maintenance, as a single tooth if broken can be readily replaced.
In this category of milling cutters, a relief to the cutting edges is provided by grinding a narrow land at the back of the cutting edges. The profile relieved cutters generate flat, curved or irregular surfaces. Form relived cutter also known as surface milling. These cutters have curved relief provided at the backside of the cutting edges. These cutters are sharpened by grinding the faces of the teeth. The form relieved cutters are used for generating formed or contoured surfaces.
The arbor type cutters are provided with a central hole having a keyway for mounting them directly on the milling machine arbor. Milling cutters having tapered or threaded holes are also available. They are mounted on arbors of different designs. The shank type cutters are provided with straight or tapered shank integral with cutter body. The straight or tapered shanks are inserted into the spindle nose and are fixed to it by a draw bolt.
The facing type cutters are either bolted or attached directly to the spindle nose, or secured on the face of a short arbor called stub arbor. The facing type cutters are mainly used to produce flat surfaces.
A milling cutter is designated as a right-hand cutter which rotates in an anticlockwise direction when viewed from the end of the spindle. A milling cutter is designated as a left-hand cutter which rotates in a clockwise direction when viewed from the end of the spindle. The parallel or straight teeth cutters have their straight or parallel to the axis of rotation of the cutter. The helix angle of parallel teeth cutters is equal to zero.
These cutters have their teeth cut at an angle to the axis of rotation of the cutter. The cutters may be distinguished by viewing it from one of its end faces when the helical groove or flute will be found to lead from left to right-hand direction of the cutter body. The cutter may be distinguished by viewing it from one of its end faces when the helical groove or flute will be found to lead from right to left-hand direction of the cutter body. These cutters are a conventional type of milling cutters whose dimensions such as cutter diameter and width, the diameter of the centre hole, width and depth of keyways, etc.
Special milling cutters are designed to perform special operations which may be the combination of several standard operations. The cutters may have standard or non-standard dimensions. This types of milling cutters are circular in shape and have teeth on the circumferential surface only.
The cutters are intended for the production of the flat surface parallel to the axis of rotation of the spindle. The plain milling cutter teeth may be helical or straight according to the size of the cutter. The figure shows a straight teeth plain milling cutter. Very wide plain milling cutters are termed as the slabbing cutter.
These cutters have nicked teeth. The nicks are uniformly distributed on the entire periphery of the cutter. The object of the nicks is to break up the chips and enable the cutter to take coarse feed.
The plain milling cutters are available in diameters from 16 to mm and the width of the cutters range from 20 to mm Fig.
The light-duty plain milling cutters have a face width less than 20 mm and are made with straight teeth parallel to the axis. The wider cutters are made with helical teeth, with a helix angle of fewer than 25 degrees. These are relatively fine-tooth cutters.
The helical duty plain milling cutters are wider cutters and are used for heavy-duty work. The helical angle of the teeth ranges from 25 to 45 degree. The cutters have fewer teeth on the periphery that increases chip space allowing them to take deeper cuts. They are also known as coarse tooth milling cutters. The helical plain milling cutters have further coarse pitch and the helix angle of the teeth ranges from 45 to 60 degree.
The cutter is useful in profile milling work due to its smooth cutting action and is adapted for taking light cuts on soft steel or brass and where wide surfaces are to be machined. The side milling cutter has teeth on its periphery and also on one or both of its sides. Before passing the metal stock from the roller the metal is at room temperature or slightly above the room temperature but below the recrystallization temperature.
This method generally requires a high compression force as metal stock is passed at room temperature. Due to high compression force the grain structure of the metal changes and forms a new shape.
Cold working is done for the brittle metal. The cold working process is used to manufacture different products in industries like large flat sheets, metal tubes, screw heads, riveted joints, and much more. Cold working is majorly used for ductile metals. As this process gives smooth finishing and strength it is also used after the hot working of metals.
By the application of the different methods of cold working like sheering, cold rolling, cold extrusion multiple products are produced. Cold-working is one of an important method of metal forming that help the manufacturing industries to produce a different variety of products. There are different methods of cold working like cold rolling, cold extrusion, cold drawing, sheering, bending but the most commonly used method is sheering and cold drawing. Amrit Kumar is a Mechanical Engineer and founder of Themechanicalengineering.
He has a Diploma and Engineering degree in the Mechanical field and writes content related to Mechanical Engineering since Many experts were working on electron beam technology in the late s. One for the tool shop, particularly useful for automotive applications. A slide hammer delivers the force of an impact without actually hitting something.
It can be used, among other things, for pulling out dents in cars. Find a good example of making a slide hammer on the lathe below. They can be made in nearly any size as well. A fun project, rather than a useful one, but handy for teaching a variety of techniques including thread-cutting. Done correctly ,you can make a pen that will accept standard ballpoint replacement ink cartridges, giving you a fully-functional, highly-personalised writing utensil.
You can build a milling attachment for your lathe, rather than purchase one. There are plenty of instructions for some highly ornamental wooden chess sets, but much the same thing can be done in metal as well. The design will be half the battle; a high-quality finish will be the other part.
The great thing about this project is the potential for a creative, highly attractive final product. The exact design of the pieces is entirely up to you, from functional, minimalist sets to highly decorative pieces.
And of course the choice of material, from aluminium to bronze, can emphasize the design of the sets. This video shows a little bit of the beauty of a modern metal chesspiece. Tubalcain on YouTube has a highly informative series on how to make a model steam engine in your machine shop. These models are fantastic teaching aids as well as challenging projects for the hobbyist.
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