What is a Die Grinder?

A die grinder is a tool used to polish and buff the inside of cylindrical objects. A cylindrically shaped sanding attachment, called a grinding nose, attaches to the bottom of the die grinder in a similar fashion as a drill bit goes into a drill. When metal piping is cut, small metal spurs often result where the cut has been made. These spurs can wreak havoc on connections. A die grinder is used to grind the spurs away, making the area smooth and allowing for proper installation.

A die grinder can range in size from a small handheld die grinder to bench top models. When choosing a die grinder, it is important to consider its primary purpose, what attachments must be used, and the amount of time that will be spent grinding down materials. An incorrectly used die grinder can wear out quickly and cause injury to the operator.

All die grinders have rotations per minute (RPM) ratings and no-load speeds. RPM measures how often the die grinder spins while in use. No-load speeds refer to the rotations of the tool’s spindle when it is idling. If the RPM rating is higher than the no-load speed, the die grinder could shatter upon use. It is essential to pay close attention to these ratings when purchasing a die grinder.

The RPM rating of the die grinder is the deciding factor in the tool’s usage. A die grinder with a lower RPM is best used for fine grinding and finishing work. Speeds lower than 10,000 RPM are best for this function. A die grinder with an RPM between 10,000 and 20,000 is great for creating rough finishes and minor buffing jobs. If the die grinder will be used to remove metal burrs or to cut metal, it must have an RPM rating of over 20,000 and a no-load speed of at least 30,000 depending on the RPM rating.

A die grinder can also utilize additional attachments. The most common attachments are large sanding disks capable of covering more space in a short time. Metric sized couplers can also be handy when using larger or smaller grinding noses.

When running a die grinder, it is important to follow some simple safety rules. Never wear loose jewelry while operating the grinder. Neck chains can easily become caught in the die grinder and cause strangulation. Safety goggles should also be worn at all times.

The operator must keep a strong hold on the die grinder at all times. Similarly, the component being ground should be held in a bench-top vice or clamp. Fingers should be kept out of range of the die grinder. When the die grinder is not in use, it should be unplugged.

What is a Knurling Tool?

A knurling tool is used in conjunction with a lathe to emboss the ends of metal tubes and shafts. The embossed grooves may act as hand grips for the user or better traction for rubber or plastic covers. The knurling tool itself consists of multiple rotary cutters which are held against the metal shaft as it turns on the lathe at a relatively slow speed (500 rpm on average). Turning is a method by which cylindrical pieces of metal or wood are spun in place by a variable-speed electric motor. As the piece spins, various cutting tools can be placed against it to remove material or cut shapes. A knurling tool falls somewhere between an engraver and an embosser.

There are generally three shapes generated by most knurling tools - straight lines, diagonal lines and a diamond pattern. Knurling tools do come in a variety of sizes and cutting designs, depending on the purpose of the piece. The diamond pattern is most common with hand grips because it creates the most traction between a user's hand and the shaft. Diagonal and straight knurls are generally used to give extra traction to an external handle or other connective piece.

In order to create a knurl pattern, the lathe must hold the metal piece perfectly straight - a condition machinists call 'true'. As the lathe begins to turn, a special holder for the knurling tool is attached to the work table. The knurling tool itself is clamped into the holder and carefully directed to the turning piece with a small crank. Since knurling is an abrasive process, the machinist should use a generous supply of machine oil on the turning shaft. A knurling tool rarely makes a complete imprint the first time it is pressed against the shaft. Machinists usually make several passes with the knurling tool, allowing the individual cutters to make small bites into the metal.

A knurling tool is best suited for softer metals such as aluminum or standard grade steel. Hard metals such as titanium would most likely ruin the tool before any embossing could take place. In commercial tool and die shops, it is not unusual to see apprentices and entry-level workers assigned to the knurling lathe set-up. Knurling shafts for screwdrivers and other hand tools can be very repetitive and time-consuming, which makes the task ideal for workers with little seniority. But running a knurling operation successfully can lead to more advanced lathe work with more interesting cutting techniques.

The Benefits of Shearing Metal Fabrication

A process of metal fabrication used in cutting straight columns on smooth metal stock is called shearing. During this process, both the upper and lower blades are enforced to pass each one with the gap between them identified by an essential offset. Usually, any of the two blades stays stationary.

The characteristics of the shearing procedure include:
- Its capacity to create straight-line slices on smooth sheet stock
- It has metal placement amid the lower and upper shear blades
- Its capability to cut comparatively tiny lengths of objects at any instance because the cutting sharp edges can be fixed at a slant to lessen the needed cutting force required.
- The trademark manufacture of rough and slightly malformed metal edges.

During the process the upper cutting blade breaks the piece of metal put in place by means of the holding devices and then the trimmed piece falls away. In general, the higher shear sharp edge is fixed at a slant to the blade bellow that is usually mounted horizontally. The cutting procedure performs only basic straight-line slicing however, any geometrical form having accurate line cut may be formed on the shear.
Metal cutting can be done on sheets, bars, plates, strips and also angle stock. Bar and angle objects can be sheared only to length, but many forms can be made by shearing sheet and plates. Materials that are usually sheared include: brass, bronze, aluminum, mild and stainless steel.

Slitting

This is another type of shearing process, however, rather than creating cuts at the edge of work piece such as shearing, slicing is being used to incise an extensive coil of metal in some narrower coils since the principal coil is stirred through the slicker. Throughout the slitting procedure, the metal loop passes lengthways by means of the circular blades of the slitter.

The characteristics of the slitting procedure include:

- Its capacity to be utilized on ferrous and also non-ferrous metals
- It is restricted only to cut relatively slim materials
- It leaves remains of burrs in slit ends of narrower coals
- Its classification as high creation is designed to manage the width of metal coil.

Slitting may be utilized equally well intended for the sheet as well as coil rolls. The slicing blades are intended depending in the work required. The three important determinants of the pattern of the blade include:

- The kind of objects to be cut
- The thickness of the piece of material
- The forbearances that should be held while doing the slitting.

The Tool and Die Making Machines

The tool and die making industry is among the most profitable industries there is. Tool and die making is a process that requires a lot of knowledge and know-how. People who decide to enter this field would need to spend several years studying everything about it and learning its different applications. In short, it is no joke to venture a career in this field.

People who are in this kind of profession are regarded highly by their fellow skilled workers. Their job is to make tools, die them, and make sure that all the objects and products created are in its best possible condition. They also manufacture clothes, pieces of furniture and equipment and car or aircraft parts. They may be found in large industrial and manufacturing plants or in average-sized machine shops.

In order for a tool and die maker to be efficient, he or she should be educated with even the littlest details about how to manufacture stamping dies, jigs, fixtures and plastic molds. Different types of materials would require varying techniques. For example, in stamping dies, force is required from the maker. However, in plastic molding, no force is needed.

As the years went on, the machineries and tools used in tool and die making have developed greatly. One notable person who played a great role in this process is Eli Whitney, an American manufacturer and inventor. His notion of interchangeable parts in planned manufacturing was revolutionary. Because of his studies, he was able to successfully mass-produce firearms and weapons for a war that occurred in 1812.

Since then, tool and die making machines have evolved greatly. The power press came out, then there's the press die, and more. Alongside this, injection molding and die casting took a leap, resulting to more demands for more advanced tools.

Tools and dies are often designed by tool designers and engineers, but a well-experienced and extremely skilled tool and die maker could also do the job. They would be asked to visit a customer's place to check out the whole operation. This would enable them to know if there's something in there that needs improvement.

Back then, they would use blueprints to plan out the necessary steps to proceed with the operation. Everything would then be done manually. Fortunately, today, CAD or computer-aided design and more modern tools and machineries are already available, making things much simpler and faster to accomplish.