CNC Machines - Scope And Utilities

The scope and utilities of the modern CNC machines have greatly increased with the growth of small and medium scale industries. The advanced CNC machines are highly portable, small in size and light weight. They are also called Desktop and Benchtop mills or lathes for their easy mobility. In spite of their compact size and design, they are proved to be highly durable as these machines too are built of heavy duty machine parts and components like their heavier versions used in heavy industries. Such mobile machines are very capable and efficient at cutting and shaping strong metals and non-metals with a higher degree of precision and rigidity.

As desktop CNC machines come with a factory acceptance test report which guarantees its safety and efficacy, the benchtop machines are increasingly getting used in school laboratories, college & higher education workshops, mini factories, hobby centres and R & D laboratories. Even using a CNC machine is not a big deal. Modernized versions of mills and lathes can be fully operated with the use of computer programming, as this operation requires less calculations and the machine does its work with good accuracy. The CNC mills and lathes are fitted with powerful motors with high rpm, so as to enable them to cut and shape even thick metallic or non-metallic sheets and boards.

Automatic and highly reliable CNC machines are very efficiently being used in small factories and workshops for the purpose of jewelry making & designing, metal molding & dyeing, cutting and shaping of surgical equipments and blades, manufacturing scientific and measuring instruments and for drilling and cutting of various objects. The systems of these high caliber machines are designed and developed using the latest mechanical and electrical engineering techniques, which give them a competitive edge over other similar cutting and drilling machines.

The desktop CNC machines are very user-friendly and safe to use, even for amateurs with just little guidance on operations. The high precision, rigid, small, handy, lightweight, powerful and durable CNC mills and lathes do not come with high cost as per the features showcased. Instead the modern high precision CNC machines could be purchased at very low and reasonable costs. Whether you want to purchase such machines for a new set-up or want to replace old and heavy machines with modern ones, make extensive research on internet about the best prices and associated features of CNC machines and make a deal only with reputed and innovative manufacturers.

Used Cnc Router Machines

Save Time With A Hydraulic Log Splitter

If you have a lot of wood to chop then a log splitter is a wise investment. You can buy log splitters to chop wood for a fire or to make furniture. You can find this type of product wherever you find other logging machinery. If you want to save some case then buy a used one or build your own. You can go online to research how to make your own log splitter.

A great hydraulic log splitter is worth consideration when you are looking into different types of log cutters. These have a diesel or gas engine which delivers power to it. The engine is connected to an oil pump that in tow gives power to the hydraulic cylinder. There is a tank that contains the oil and you must change this out every once in awhile.

Hydraulic Log Splitter Features:

-You can choose an engine that goes from 5-8 horsepower.

-One for your personal use will have a smaller engine than one that you use for business. -You can get 10-25 tons of splitting power.

-It will have a 2-stage oil pump.

You will normally used a log splitter on your own property if you want to cut up firewood. You must first remove all the branches from a tree with a chainsaw and then you can cut down any parts of the trunk into smaller pieces. After words you can cut them with your splitter. Having a machine can help you shave hours or even days off of this kind of tedious job.

How To Be Safe

-Never allow kids around the splitter.

-Never allow children to use the equipment.

-Make sure to wear sturdy boots to protect your feet.

-Don't wear loose clothing or long sleeve shirts that could get caught in the machinery.

-Always use safety goggles.

Make sure you know how to use your splitter before turning it on.

-You should look over all the instructions thoroughly before you turn it on.

-You also want to make a safe area around your machinery to protect people from logs or debris that may fly.

-You should also never use it when you are drinking or if you are on drugs.

-Don't use it in a slippery area.

-Only use it for its intended purpose.

-Never remove the guards.

If you want to use your splitter for something other than cutting wood, you can try your hand at making furniture. You will also need a chainsaw if you want to make furniture.

Here's a sample list of the thing you'll need to get started making wood furniture today:

-Clamps for holding things still

-Instructional information

-Large sized chisels

-Corner and framing chisel

-Mallet

-Tenon maker

-Guides for woods to shape them and in different sizes

Work Holding Devices Milling Machine

Magnetic Lifters for Heavy Load Operations

With a lifting capacity of exceeding 25 tons, magnetic lifters are well suited for a wide range of applications.

Magnetic lifters are an ideal material-handling solution for transporting heavy loads of ferro-magnetic material, such as steel plates, forgings and die castings, safely without the use of clamps, slings, chains and other holding devices.

Types of Magnetic Lifters

There are three types of lifting magnets: permanent, electromagnet and electro-permanent. While they all can safely transport heavy loads, each type has its application specific advantages.

Permanent magnet lifters, made from rare earth or ceramics materials, use permanently magnetized material to generate the lifter's magnetic field or holding force. They do not require electrical power, which eliminates hazards caused by power interruptions and gives them the added benefit of portability. They are manually operated using a lever located on the lifter. A safety latch is typically built in to ensure that the magnet is not accidentally turned off while performing a lift. However, one disadvantage is that permanent magnets have a non-variable lifting capacity.

Electromagnetic lifters use an energized electrical coil wound around a steel core embedded in the lifter to generate the magnetic field. A D.C. controller or rectifier provides the excitation voltage to energize the magnet. This voltage can be varied and gives the electromagnetic lifter another benefit: variable holding power. However, the primary disadvantage is they require the continuous application of electrical power to operate. So, a power failure would de-energize the magnet and create a potential safety hazard. To overcome this problem, an uninterruptible power supply (backup system) would need to be integrated into the lifting system.

Electro-permanent magnetic lifters are a combination of the permanent and electromagnetic types. They use permanent magnetic material that is turned on or off by a D.C power supply, which can be supplied by a D.C. controller or a battery, but electricity is not required at all times. The battery would require periodic recharging, however. Since they only need electrical power to turn the lifter on or off, they have a built-in failsafe operation.

Retrieving and Scrap Applications

Lifting magnets are the perfect solution for retrieving material from obscure, difficult-to-reach, or dangerous places. They are commonly used in underwater applications to retrieve metal from a damaged submerged vessel like a sunken ship or wrecked oil well. Lifting magnets in these applications are called retrieving magnets.

Larger, heavy-duty lifting magnets are often called scrap magnets. They can be used to lift large objects like scrapped vehicles. Specially designed, scrap magnets have the ability to lift large coils of wire without the unwinding or telescoping of the coil.

Other Advantages

There are many other advantages to gain from lifting magnets. They include:

Eliminate Drilling Tap Holes: the need to drill and tap holes in materials prior to lifting is many times required to obtain an anchor point or eyebolt to latch onto. In many instances after lifting, the eyebolts need to be removed and the holes filled up, which can add to the cost of the product.

Easily Palletized: Magnet lifters are particularly useful if individual parts from a stack or crate of parts need to be moved. By accessing the part with a lifting magnet, it can be lifted vertically out of the crate or stack.

Using A Cnc Press Brake Machine For Custom Roll Forming

A press brake is a machine used in secondary forming of laser cut or punched sheet metal. The biggest advantage of press brake is the enormous sizes of work pieces that it can handle. It is amazing to note that the bed length of a press brake can range from 4 to 14 feet and it can roll the sheet metal with a force varying from 25 tonnes to over 250 tonnes.

Almost all the tools used in press brake rolling are standard and these standard tools can be used for almost any formed shape and part size. A press brake is an ideal machine for rolling medium and small run steel fabrication services. A CNC press brake is the most popular machine being used for rolling sheet metals these days. CNC stands for Computer Numerically Controlled which brings high level of precision in finished product. Although hybrid electric and hydraulic machines are the latest in the industry right now, CNC continues to be the most popular machine.

A CNC press brake machine is programmed with automatic back gauging that can go up-down and in-out. It provides depth stops for accuracy and repeatability. A CNC press brake has multiple tools, both stock and separate for handling various bends with just a single setup. This advantage of a CNC machine makes it an obvious choice for custom roll forming operations. An operator can set multiple tool stations over the bed of one press brake, which allows the whole process to be carried out at a better pace as compared to other press brake machines. A CNC press brake forming machine can make the whole process more competitive in the industry. A CNC press brake can also be used to form ribs in different parts of the material without having to change the gauge of the material.

A CNC press brake forming brings high degree of precision in the entire process. The tolerances achieved in the process are however similar to forming or cutting processes that were used to make blanks before press brakes came into operation. A CNC machine can be used to handle large production volumes and complete the finished product along with a high degree of precision. Spare parts for a CNC press brake machine are easily available with local vendors and hence the overall operations cost of the machine is not high.

Popular Cost Effective Alternatives to Metal Stamping

In the context of metal forming, the process of metal stamping comprises of several different press forming operations such as punching, bending, flanging, coining, blanking etc. For a sheet or tube of metal to be made useful, it needs to be formed. These processes have been in use for several decades and have evolved with the emergence of newer techniques over the years. Despite this, there are certain drawbacks associated with stamping that tend to delay or adversely affect commercial or industrial projects.

For instance, the biggest challenge is investment in tooling systems. The entire set-up requires a significant capital investment, the cost of which is passed on directly to customers. Another aspect to consider would be production volume. Most companies that cater to industrial players often find it difficult to cater to small production volumes. Even if they do agree to deliver a limited batch, the cost per part is significantly high. In such a case, the lead times tend to be longer too.

With these drawbacks of stamping become more evident to industries, there is a growing inclination towards alternative methods such as sheet hydroforming and metal spinning. Interestingly, the tooling costs of these alternative methods could be up to 85% less than conventional stamping tooling costs. While there are several companies that offer such services, there are only a handful of companies that offer world-class metal forming and fabricating services.

Let's take a look at the benefits of these alternative metal forming methods:

Metal spinning: Also referred to as spin forming, this method allows a fabricator to use a metal disc or tube to turn it into an axially symmetric part. This is achieved by spinning the metal on a high-speed lathe. In some cases, the spinning process is carried out manually too. Different types of ductile metals can be formed using this particular method. The metal spinning technique is very cost-effective and is also suitable for high volume part production.

Hydroforming: This technique involves the use of highly pressurized fluid for shaping and contouring a metal sheet. Whether it is a smooth contour or intricate angles, you can achieve a well-finished part using this method. This is one of the most cost-effective methods of shaping ductile metals like stainless steel, aluminum, and brass among others. The parts thus formed tend to be structurally strong, which explains why automobile industries are increasingly using this method.

Parts formed using these techniques are compliant with the prevailing industry specifications.

The aerospace and defense sector, automobile industries, nuclear industry, furniture manufacturers, and the HVAC sector are increasingly opting for forming methods other than metal stamping. These methods are capable of producing just about any part or component that one might expect to achieve through metal stamping.

Ways to Address the Shortcomings of Metal Stamping

The background

In the engineering and manufacturing sector, metal stamping has been conventional the chosen part-forming process. Metal stamping entails the use of various processes such as punching, embossing, bending, flanging, and so on. These processes are typically carried out on sheet metal using a stamping press or machine press.

As various industries evolved, the need for more complex and cost-effective forming processes became evident. With this, certain disadvantages pertaining to stamping came to the fore. Though traditionally popular, the stamping process has certain drawbacks that simply cannot be ignored by a new-age business. This article elucidates the shortcomings of traditional stamping methods, and other forming methods that can be employed as suitable substitutes.

The drawbacks of metal stamping

Here are some of the commonly known drawbacks associated with the stamping method:

Costs: The various pre-production and tooling costs related to stamping are high. These costs ultimately add to the cost-per-part. In many cases this high initial investment is uncalled for. However, since businesses aren't aware of other options they often agree to spend more than what is required.

Versatility: Custom tools usually need to be created before the stamping process can begin. This not only adds to the initial investment, but it also means that even the most minor change in design cannot be accommodated.

Production volumes: While there is little doubt about the fact that metal stamping proves economical in large volume production runs, it is rather unsuitable for smaller production runs. The high initial tooling investment is the main reason for this.

Lead times: From design to tooling to production, the lead times taken for the metal stamping process are often long. Thus, if one has a super rush order and cannot afford to waste precious time, they would want to rethink about choosing stamping as an option. So, what are the alternatives?

Metal spinning and sheet hydroforming are the definitive alternatives to the traditional metal stamping process. These processes can mitigate almost all of the drawbacks relating to tooling costs, production runs, and part quality that are associated with the stamping process. Hydroforming is a technique of shaping a metal using a highly pressurized fluid. This method is preferred for parts that have complex contours, yet need to maintain their structural integrity. Metal spinning-also referred to as spin forming-entails shaping a metal disk into an axially symmetrical part on a high-speed spinning lathe.

Both of these methods can be successfully used for forming high quality metal parts from various metals such as stainless steel, aluminum, and even brass. These metal forming services should ideally be availed from experienced firms with an established portfolio in providing alternatives to the metal stamping process.

The Process Of Die Cutting, What Is Its Advantage?

Die cutting is a process of cutting different materials through the use of devices. What are the materials? You cut plastic, leather, paper, metal, cardboard and textile. What device is used to cut? The tools used in the cutting process are steel stamps and rollers. The process is widely used now for industrial purposes such that more materials are being cut. The additional kinds are rubber, vinyl, wood and magnetic strips.

In the cutting of any of the materials, a metal die or template is used. You will have a predetermined shape and size and this will be the basis of the cut. So you can cut shapes and sizes, you can also cut alphabets, geometric shapes and form pictures. There are two methods employed in die cutting. These are the steel rule and the rotary or flat bed method. To give shape to the materials, the die cutting method is called steel rule. This same method will create the creases, holes or perforations and slits on the material. The rotary or flat bed method makes use of tungsten carbide in the process of cutting.

Given the method, the die cutting process begins when the material and the die is placed on the cutting machine. There are machines that use another machine like the presses in order to create the designs on the materials. These presses can be small and large, where the small kinds can exert a force equal to 20 tons. The large types of presses can exert as much as 150 tons of force. Today, many industries are already using die cutting and in such big companies, the die cutting is atomized. In the die cutting process, the materials are fed automatically to the cutting machine, then pressed and cut. Having been cut, the output is removed.

Die cutting is not only for business and industrial purposes. Any household may have some need for the small die cutting machine that is designed for domestic use. These cutters are usually available from craft store. There are also small die cutters that can be purchased online. The price is affordable and the cost is dependent upon the size. For household use, the die cutting is used in the designing of book covers and picture frames.

The die cutting process is found in different areas of industry. The distinctive shape created is one aspect for sales products. This makes the die-cut labels produced in die cutting as a real marketing instrument. With the die cutting process, you can also make library aids, educational or mathematical materials, invitations, greeting cards and more. This process also creates home decors, scrapbooks, embellishments, accessories and other crafts.

Today, the technology employed in die cutting has evolved at a very fast pace. This paved way to the use of laser technology give rise to the laser die cutting process. As innovations and technology progresses, it is expected that the die cutting process will be more sophisticated in the years to come.

The Explanation Of Die Cutting And How It Operates

If you've never heard of the expression contract die cutting, there are actually a lot of other people who are also oblivious to this. This is probably because OEM die cutting is not a usual term in today's society, for those who require more information about this technique, there is a lot of information which can be found on the internet. It is necessary to know what this is so that you will be able to identify what the procedure is.

By meaning, die cutting is being utilized as a manufacturing process so that large numbers of a similar shape can be produced. The majority of the materials being utilized for die cutting include plastic, fabric, metal or wood, apart from these, other materials can still be made use of. In the leather and metalworking industries, the die cutting method is also known as clicking. To add, it goes through a machine which is known as a clicking machine. Once a dinking machine is used, it is known as the dinking process. The dinking process makes use of common materials like cardboard boxes, envelopes, labels and gaskets.

The practice of die cutting is being used so as to cut large amounts of a similar shape. The shapes that have already been cut are being called blanks. This is because they are usually decorated and finished prior to being sold. The entire process of die cutting is largely being utilized in an assortment of materials throughout the world. Many of these manufactured commodities have several die cut parts. Most of the time, these have been assembled together in a compilation of steps in order to derive to a finished product.

The Die Cutting Process

Throughout the whole process of die cutting, the blades which are being used are sharp and have been specially shaped. These blades have been bent into a desired shape that has been affixed to its strong backing. As an outcome, a die is produced. To start the process, the intended material to be used is being set on an even surface that has a strong backing. When this has been achieved, the die is being pressed onto it so that it will be cut. The amount of cuts pressed onto it will rely on what is being made. If the material only needs a piece then a single die gets cut into it but simultaneously, multiple layers can also be calculated to cut the material so that it will produce a stack of blanks.

In a way, die cutting can be evaluated to a cookie cutter. This is because they are both accountable for what the shape of the blanks will result to. In addition, all of these blanks will be of a similar size and shape with one another. For this, each of the blanks that have undergone the process of die cutting is uniform with one another. Rather than using this process, it can still be cut by hand. But this is not recommended as it is timely and can produce a number of inconsistent shapes and sizes.

All About Burrs

INTRODUCTION

Burrs which are also known as rotary files which consist of small and large shaped cutters used in die grinders, rotary tools, and dentist's drills. The name may be considered suitable when their mini-size head (3 mm diameter shaft) is closely similar to that of a seed in the burr fruit. Carbide burrs are also used in CNC machining robot "type" centers for removing burrs (the small flakes of metal) after a machining process (Burrs-cutting, n.d.) To sustain the right external speed and cutting environment they are rotated at the maximum velocity achievable, appropriate with their size and structure.

In engineering, a burr can be described as the raised circumference on metal. It may be present in the form of a fine wire on the edge of a freshly sharpened tool or as a raised portion on a surface, after being struck a blow from an equally hard or heavy object. Specifically, burrs are as a rule useless residual that is the effect after machine grinding, drilling, milling, or turning. In the following report the word, burr, refers to the excess substance of material and carbide burr refers to the tool that removes the excess material.

Deburring

The process of removing burrs, the small flakes of metal, is known as deburring. Burr creation in machining accounts for a major part of the costs for manufacturers throughout the world. Drilling burrs, for example, are common when drilling almost any material. The Boeing 747 airplane has approximately 1.3 million holes drilled in it most of which have to be deburred to some extent (Burrs-metal, April 2007). As one could imagine, the cost and time needed to perform these drilling and deburring operations is significant.

In addition to drilling, milling is also a source of burr formation in machining. A good example of unwanted burrs is in the automotive industry where cylinder blocks, pistons and other engine components are cast then milled to a specific dimension. With higher demands placed on accuracy and precision, burr formation is of critical importance because it can affect engine performance, reliability, and durability (Burrs-metal, April 2007).

Tungsten Carbide

Burr cutters are made from tungsten carbide which allows them to move at high speeds and yet still sustain their cutting edges. Carbide cutting surfaces are often useful when machining through materials such as carbon and stainless steel as well as in situations where other tools would wear away, such as high-quantity production runs. Usually, carbide will leave a better finish on the tool, and permit quicker machining. Carbide tools can also endure higher temperatures than standard high speed tools. The material is usually tungsten-carbide cobalt, also called "cemented carbide", a metal matrix composite where tungsten carbide particles are the aggregate and metallic cobalt serves as the matrix (Tungsten Carbide, n.d.)

USES & APPLICATIONS

Carbide burrs are used for rapid removal of excess materials. Ironically, burrs are both referred to as the excess shavings of material and the actual carbide burr "tool" used to remove rough edges after the machining process. The removal of burrs from jagged, sharp edges is another common application for carbide burrs. In addition, carbide burrs are a supplemental type of tool that is used prior to polishing or finishing with coated abrasives. Carbide burrs can be used on cast iron, steel and aluminum. Depending on the type of surfaces that are accessible, carbide burrs can be utilized because of the different shapes in which they are manufactured. Typically, carbide burrs are made in ½ inch diameter shapes such as round, cylindrical and oval. Carbide burrs are created with different cuts. Single or double cuts are used for steel and cast iron surfaces. According to Monroe (1997, p. 28), a course single cut minimizes the tendency of the cutter to load up with aluminum.

A die grinder is a handheld tool which turns a burr at a high rate of speed. It is usually pneumatic (powered by compressed air), although electric die grinders are also common. The burr is held in a bit holding device and may be changed as required. The rotational speed of a pneumatic die grinder is adjusted by a hand-operated throttle which allows the operator to fluctuate the volume of compressed air entering the tool. Die grinders are used to drudge away small amounts of metal from piece of work. The name comes from their use in touching up hardened steel dies (Die grinder, n.d.).

Porting is another method in which application of the carbide burr is necessary. Cylinder head porting refers to the process of modifying the intake and exhaust ports of an internal combustion engine to improve the quality and quantity of the gas flow. Porting the heads provides the finely detailed attention required to bring the engine to the highest level of efficiency. Theoretically, polishing with abrasives affects the fuel flow and ultimately the porting process is responsible for the high power output of modern engines (Cylinder Head Porting June 2008).

Lastly, another common application and use of the carbide burr is utilized by sculptures. They provide vibration-free cutting and grinding. The shank is made of high tensile stainless steel. Diamond burrs are created by bonding diamond particles by means of electroplating with uniform size and exceptionally sharp-edged for fast cutting. Carbide burrs are precision fluted and can cut just about any material such as bronze, brass, aluminum, steels, wood, and all types of stone.

FUTURE OF CUTTING TOOLS

In the late 1990s, a total of 2,096 establishments operated in the industry. In 2000, hand and edge tool manufacturers shipped $7.6 billion worth of goods in 2000, while cutting tool and machine tool accessory manufacturers shipped $5.6 billion worth of goods (Cutting tools, machine etal, n.d.).

According to the United States Census Bureau (2002), cutting tools, machine tool accessories, and precision measuring devices industry is facing transition. Increased global competition in all aspects of manufacturing has created demand for better, longer lasting tools and accessories. Extensive development of tougher cutting tool materials and coatings has been the driving force of change in this industry, along with improved cutting tool design that lends extended performance. Increased emphasis on quality control is affecting the measuring device segment through demand for electronic gauges that link to statistical process control software packages. Modular tooling designs have affected the accessories segment.

A downturn in the machine tool industry does not necessarily correlate to the health of the cutting tool industry. Generally, cutting tool sales are viewed as an economic indicator of the nation's manufacturing productivity level. The difference primarily is capital expense. A corporation may decide to purchase a used machine tool over a new one in recessionary times. However, if a company is cutting metal, the cutting tools wear or break and must be sharpened or replaced with new cutting tools. Therefore, the productivity of a metal cutting company generally is directly related to the purchasing levels of machine tools. However, longer lasting cutting tools are being manufactured with specialized coatings that extend the wear life of the tool—sometimes as much as four times the normal wear. With improved cutting tool materials and geometry, the volume of machine tool sales will inevitably drop because the tools are designed to reduce the frequency of replacement (Cutting tools, machine etal, n.d.).

What Are Tools and Dies in Basic Terms?

Sometimes it is nice to find information that is simple and doesn't use big terms. Then the answers can really be answered and understood. That is the biggest challenge, being able to understand. Let's take a look at tools and dies.  Tools are used to build something and dies could be the dye that we use to color something or the die cut that you use to cut paper. That isn't what I am talking about. Let's put these terms together and see what great things we can come up with.

Let's break it down so it is understandable. A die is a specialized tool that is used to cut, shape and form a wide variety of products and components. It is commonly used by manufacturing industries. Some of the simple things that have been made with a die is a paper clip. That seems like a simple thing, but think of how often we use a paper clip. Some of the other common items that are made with a die is a metal spoon, fork and knives. Also, aluminum cans, clothing zippers and buttons. Then there are several different car parts such as: car fenders, bumpers, doors, hoods, pistons, rods and the frame.

In order to make a die it is formed by tool and die makers. The die is a metal block. Once the die is made it can be used for forming material such as metal and plastic. For plastic it takes single plastic sheet to form transparent plastic containers. This uses a vacuum forming process. When you are doing metal it takes a sheet of metal and can perform two different parts. One is called the punch and it does the steps of stretching, bending and/or blanking the operation. The other part is called the die block which securely clamps the work piece and does similar actions.

It takes both the tools and dies to be able to perform all of these different things to create these things that we use in our daily routines. One goes with the other. The tools are needed to create the dies that are going to become the mold to make anything imaginable. The process is fascinating and it is amazing what creativity, tools and dies can come up with.