Machining processes are opted for a wide range of components. Among the different types of machining processes, grooving is also opted for part manufacturing. It is used in conjunction with lathe machining, and if you want to learn more about it, the guide below has it all. So, let's read.

What is Grooving Machining?

Grooving machining is a process that is conducted using a CNC lathe. The process of grooving machining consists of creating holes and channels on a workpiece. The channels and holes created using grooving machining have boundaries, and they help to assemble the parts together.

Types of Grooving Machining

There are different types of grooving machining processes, and some of them are discussed below.

Straight Turning

Straight turning is a method in grooving machining that is compatible with cylindrical components. The process rotates the part, and a cutting tool creates a consistent and straight groove that moves parallel to the workpiece. It is suitable for creating grooves on rods, shafts, and other components having a cylindrical shape.

Face Grooving

Face grooving uses the CNC lathe to move along the face of the material using the grooving tools. It uses the shortest depth for cutting and requires high precision using coolants to ensure enhanced chip removal.

Contour Grooving

Contour grooving is a grooving operation that creates curved and non-linear grooves on the component. It follows a path that has a variation in width and depth and hence creates complex shapes. It is mostly opted to design special components in the aerospace and automobile sectors, and create stepped and tapered grooves.

Internal Grooving

Internal grooving is a process of machining that creates grooves on the internal part of the component. In cylinders, pipes, and other hollow parts, these grooves are created. It is mostly chosen for hydraulic cylinders and pipes to create internal grooves.

External Grooving

External grooving creates grooves on the outer area of the parts, which have a cylindrical shape. The specialized tool for grooving moves along the outer diameter of the component and creates a deep and wide groove. It is mostly opted for tubes and shafts creating the grooves to support functionality and assembly of the components.

How To Groove with CNC Machines?

The process of grooving with CNC machines is very straightforward and has some steps to follow; these are given below.

Step 1: Secure the Workpiece

The component is first secured on the machine with perfection because even if it moves a little, the flaws in the component may appear. You should place the part in the chuck of the lathe and then lock it or fix it with the screw and mark the groove position.

Step 2: Load The Tooling Devices

The tooling devices are selected based on the required grooving type and loaded in the lathe tool.

Step 4: Set Up the CNC Machine

The CNC machine requires setting up where it is switched on and all the axes are brought on tier 0. The lathe is adjusted according to the RPM setting because every groove will need a different setting.

Step 4: Perform the Grooving Operation

Once the program is uploaded, the grooving operation starts, and the workpiece rotates; the grooving tool removes material from it.

Step 5: Undertake Quality Checks

Once the process of grooving the component has been completed, clean the component and check the grooves for accuracy and precision.

Considerations When Choosing A Grooving Tool

When selecting a grooving tool for the process, some of the considerations to have in place are as follows:

Material Type

Every material has different properties like heat resistance, rigidity, and hardness, and all of these play a vital role in tool selection. When choosing the grooving tool for a hard material, the tool itself should be made of carbide.

Groove Geometry

The geometry of the groove also requires analysis when selecting the tool. You must analyze how the grooving tool will interact with the chosen material. You need to assess the groove's width, depth, and shape and ensure appropriate chip evacuation is planned.

Cutting Parameters

Cutting parameters like feed rate, cut depth, and speed of cutting impact the surface finish, durability, and chip control. Hence, it is important to ensure appropriate cutting parameters are in place to prevent the breakage of tools.

Tool Selection

The selection of a tool impacts the life of the tool surface finish of part and chip evacuation during the process. Try to opt for cutting tools that ensure smooth grooving, leaving behind a seamless surface finish.

Chip Control

During the grooving operation, effective chip control is significant as it ensures surface finish and even enhances the tool's life. The right grooving tools that have appropriate geometry will control the chip, and the application of coolant helps reduce the chip formation.

Machine Setup

Appropriate machine setup is very important for effective grooving operation. Make sure to align the tool and workpiece with a stable setup. The stability of the setup ensures that the vibrations are minimized and cutting efficiency is maintained.

Types Of Grooving Tools

The three different types of grooving tools are discussed below.

Face Grooving Tools

The face grooving tools are used for creating grooves on the face of components. The tip of the tool needs placement above the component’s center line. Also, the radius of the tool should be equal to the component’s cut radius.

Outer Diameter Grooving Tools

Outer-diameter grooving tools work on the outer part of the component. The results of this grooving are excellent, provided that the tip of the tool is placed below the center line.

Inner Diameter Grooving Tools

Inner-diameter grooving tools create grooves on the inner part of the component. The tool must have its upper part above the centerline, which helps achieve accurate cuts and prevents chipping.

The Impact of Material Choices on Grooving Machining

Grooving machining is seamlessly conducted on some materials, and hence, the results are highly dependent on the material choices you make.

The best materials for grooving are stainless steel, brass, and aluminum. These materials are known for their excellent machinability. They also do not break easily, which reduces the chips, and an accurate surface finish is achieved.

How to Improve Grooving Machining?

In order to improve the accuracy and results of grooving machining on your components some of the tips you can follow are given below.

• Make sure to use calipers and steel rulers when opting for the grooves that require low precision. For grooves that need high precision, make sure to use plug gauges and vernier calipers.
• The role played by cutting speed and feed rate is very important during the process of grooving and make sure to start with a low feed rate and gradually move to higher.
• As there are different types of grooving tools, it is important to choose the one that is suitable for your component. Hence, the nature of the components and the grooves required before choosing the tool must be analyzed.
• Cutting fluid and coolants help to keep the temperature of the surface under control and even help in chip evacuation.

FAQs

What is the difference between a slot and a groove?

The slot has a long and straight hole, and its edge has a complete radius. A groove is a cylindrical slot that can be cut internally or externally.

What type of material is best for making grooving tools?

The materials for components that are subject to grooving are mostly hard. Hence, the tools should also match the hardness of the material. Therefore, steel and carbide tools are mostly chosen.

Is it necessary to coat grooving tools?

It is not necessary to coat the grooving tools, but coating them improves their life and makes them corrosion-resistant.

Brackets are used as a secondary component to help in assembling different parts together. Manufacturing sheet metal brackets must be precise and it uses specific materials for a durable finish.

If you are looking for essential information on sheet metal brackets, the guide below can help.

What are Sheet Metal Brackets?

Sheet metal brackets are also called flat metal brackets which help in attaching one component to another. It helps to align parts together, which have an enclosure, by providing additional support. The type of bracket determines whether it is welded with the sheet metal component or mounted with the hardware.

How Do We Process Sheet Metal Brackets?

The sheet metal bracket manufacturing process has different stages, and these are discussed below:

Cutting

The stage of cutting consists of using a laser cutter to cut the metal sheet based on the given size requirements.

Forming

The metal piece that is cut is bent either at one or multiple angles and uses a press brake so that the required shape is attained.

Punching

The punching process helps in creating holes in the sheet metal bracket so that it can be mounted on the walls.

Welding

Brackets, which are meant to turn the materials to be stiff, are welded together.

Different Types of Sheet Metal Brackets

There are different types of sheet metal brackets, each with a different shape to suit multiple purposes. The different sheet metal bracket designs are discussed below.

L-Bracket

The L-bracket is the most common one, consisting of a single bend that creates the L-shape. It is bent at 90 degrees and can go up to 120 degrees.

U-Bracket

U-brackets are the ones that have two bends, which create a U-shape. They are longer than L brackets and need multiple holes to mount with the hardware. These brackets are suitable for mounting surfaces that are parallel to one another.

Z-Bracket

Z-brackets are the ones that have parallel flanges in opposite directions with two bends. They make a Z shape and are used to attach components at different levels.

Gusset Bracket

Gusset brackets are added to the metal parts to enhance their fortification. They have a triangle shape and are used in applications associated with infrastructure like bridges.

Offset-Bracket

An offset bracket is a type of bracket that has a multipurpose plate. It helps to keep the frames attached to the walls and is ideal for steel hangers that have a rectangular shape.

Hat Channel Bracket

The hat channel brackets are hat-shaped brackets that have been welded within the parts and are made using weak materials. It keeps the parts protected against collapsing inwards.

Materials for Crafting Sheet Metal Brackets

There are different materials that are opted to craft sheet metal brackets, and these are as follows:

Steel

Steel is a very strong and durable material that is used in many structural applications. It is easy to alloy with other metals, and the corrosion resistance and other properties can be improved.

The applications of steel brackets are seen in construction, automobile, and manufacturing; these are heavy-duty brackets used in high-strength applications.

Stainless Steel

Stainless steel is resistant to corrosion and staining. It offers excellent durability in harsh environments. It is used for manufacturing brackets, which are used in marine, medical, and food processing applications.

Aluminum

Aluminum is always known for its lightweight structure and excellent electrical conductivity. Aluminum brackets are popular in aerospace and electronics due to their high strength-to-weight ratio.

Brass

Brass is an alloy of zinc and copper and is known for its excellent aesthetic appearance, electrical conductivity, and corrosion resistance.

It is used in applications that require aesthetics and functionality. Applications like hardware, electronic components, and musical instruments tend to use brass brackets.

Surface Finishes for Sheet Metal Brackets

There are different surface finishes for sheet metal brackets, and some of these are as follows:

Powder Coating

Powder coating uses dry powder, which is applied electrostatically to the surface of the sheet metal bracket. After application, the bracket is left to cure under heat so that a tough layer is created to keep the bracket from chipping.

Bead Blasting

The bead blasting process involves creating a uniform matte finish on the sheet metal bracket. The fine particles of glass or metal are blasted on the sheet metal bracket at high pressure and speed, which ensures that the surface of the bracket turns smooth.

Plating

The process of plating involves creating a layer of metal like zinc, nickel, or chromium on the sheet metal brackets, which makes them resistant to corrosion.

Anodizing

The process of anodizing is usually opted for aluminum brackets. The process converts the surface of the bracket equipped with an anodic oxide finish, which makes it durable.

Applications of Sheet Metal Brackets

There are many applications of sheet metal brackets, and some of these are as follows:

Automotive: The automobile industry uses sheet metal brackets in the exhaust system and vehicles' engines. These brackets offer stability in the structure and can withstand high temperatures.

Electronics: Sheet metal brackets allow us to assemble the enclosures and circuit boards, and they also help with cable mounting. These brackets help secure the electrical components better.

Construction: In construction applications, railings, beams, and panels are secured through these brackets. They also help count the shelves and frames. The sheet metal bracket provides a strong hold of these components against loads.

Aerospace: Aerospace applications use sheet metal brackets in fuel lines, navigation tools, and aircraft panels. The aluminum brackets are lightweight and enhance fuel efficiency.

Key Factors to Consider When Designing Sheet Metal Brackets

When designing the sheet metal brackets, some of the important factors to consider are as follows:

• The materials selected for manufacturing the sheet metal brackets should be corrosion-resistant, capable of handling weight, and within the budget.
• Ensure that when assessing the amount of weight, the bracket requires supporting so that the design takes into consideration that force to avoid deformation.
• The conditions in which the sheet metal brackets will be used are also a factor to take into account. Hence, choose a material that can withstand the surroundings.
• The design of the bracket should consider the appropriate bend radius, tolerance, and hole spacing so that it can be used for multiple purposes.
• The method of installing and securing brackets is also a point to consider to ensure secure installation.

Conclusion

Sheet metal brackets are meant to be used in many applications, and hence, it is important to ensure that the design considerations are aligned.

DEK offers custom sheet metal brackets designed with high precision for your projects, so get in touch with us today.

There are many types of metals and each of them has a different composition, property, and nature. Along with heavy-duty metals, the demand for lightweight metals is quite common in some sensitive industries.

If you want to know about these lightweight metals, this guide features detailed information. So, let's read.

What is Light Metal?

Lightweight metals play a vital role in manufacturing components for many industries, such as aerospace, electronics, and automobiles.

They are known for their lower weight, which helps attain fuel efficiency for vehicles and aircraft and enhances their aesthetics.

Types of Lightweight Metals

The three different lightweight metals are discussed below.

Aluminum

Aluminum is known for its excellent properties, corrosion resistance, strength, and lightweight. Aluminum is alloyed with different non-ferrous materials, and hence, it has enhanced physical properties.

There are different grades of aluminum, and each grade offers durability, corrosion resistance, and ductility.

Aluminum conducts electricity and heat. It offers excellent machinability and castability as they have a moderate flowability and melting point.

Pros of Aluminum

• Aluminum offers resistance against corrosion.
• It has a weight of around one-third of steel, which makes it a perfect lightweight choice.
• It can be recycled.
• Aluminum alloys are known for thermal and electrical conductivity.
• Aluminum is highly formable and machinable.

Cons of Aluminum

• Certain grades of aluminum are highly expensive.
• Aluminum may sometimes need heat treatments to achieve the required properties.

Applications

• In marine industries, propeller shafts and boat hulls are made with aluminum.
• Car bodies, wheels, and even engine blocks in automobile industries use aluminum.
• Electronics, circuit boards, housings, and heat sinks are made of aluminum.

Titanium

Titanium is a lightweight material that is known for its high strength. It has low density, high tensile strength, and offers toughness when exposed to high temperatures.

However, titanium's machinability is very low due to its hardness and low heat dissipation; hence, specialized machining tools are needed.

Pros of Titanium

• The strength-to-weight ratio of titanium is high.
• Offers high resistance against corrosion
• Titanium offers recyclability
• It has a low modulus and, hence is less stiff.

Cons of Titanium

• Titanium is very expensive
• It has low machinability due to hardness
• It has low thermal conductivity.

Applications

• Structural components, exhaust systems, and engine parts for aircraft are manufactured using titanium.
• Bicycle frames and sports gear are manufactured with titanium alloys.
• In the power generation sector, heat exchangers and turbine blades use titanium.

Magnesium

Magnesium is a metal that has a gray color and shiny surface, a low melting point and density, and high chemical reactivity. It is a very light metal. It consists of silicon, manganese, zinc, and aluminum.

Pros of Magnesium

• It offers excellent dimensional stability
• The high castability of magnesium makes it suitable for metal casting.
• It offers high-impact resistance
• It is very lightweight.

Cons of Magnesium

• It has a very low melting point.
• It can catch fire due to high flammability.
• It is not corrosion-resistant.

Applications

• Wheels and engine blocks of automobiles are manufactured using magnesium.
• The interior parts of an aircraft and landing gear have magnesium alloys.
• In industrial applications, it helps to manufacture machinery parts, power tools, and frames of structures.

Table Comparison of Lightweight Metals

The table below, at a glance, shows the properties of aluminum, titanium, and magnesium.

Common Ways of Processing Light Metals

Some of the ways of processing light metals are as follows:

Forming

Forming is a technique of metal processing in which the metal is converted to a usable form. It has different methods like extrusion, bending, brake bending, press drawing, and roll bending.

It takes place at high temperatures, and it is mostly used for forming magnesium extrusion.

Powder Processing

Powder processing consists of applying pressure and heat to the powder so that the components with a hard texture are formed. This powder is created from molten metal, and it is then passed through a nozzle in the presence of inert gas or water spray.

It breaks it into droplets, which later are converted into powder. The metal powder is then sprayed to create blanks, which are shaped later on.

Melt Processing

Melt casting is a process in which the molten metal is poured into the mold, and when it cools down, a hard component is achieved. There are many methods for this, like thin wall casting, high integrity casting, and dissimilar metal casting.

Thermo-Mechanical Processing

Thermo-mechanical processing is a method of processing that looks after the thermal and deformation, which enhances the properties of the material. It allows the creation of components at a low cost, and these components are lightweight and high-precision.

The temperature, deformation, and cooling are precisely managed during the process, which helps optimize the material's microstructure.

The need for reheating and quenching is eliminated. This processing method is suitable for aluminum and titanium and enhances their fracture resistance, strength, and fatigue resistance.

CNC Machining

CNC machining is also chosen for processing lightweight materials by using CNC technology to create components that are highly precise.

However, every material has a different response to machining; aluminum is highly machinable, but magnesium isn't and needs care.

The process of CNC machining allows the manufacture of components that have high dimensional stability and tight tolerance.

How to Select the Suitable Lightweight Metal?

When selecting the lightweight materials, some of the important considerations to keep in mind are discussed below:

Mechanical Properties

The mechanical properties of the metal must be analyzed, which includes considering the ductility, strength, machinability, and durability of the material.

Aluminum and titanium have the ability to handle stress. Hence, applications that need such type of component can be made using aluminum and titanium.

Thermal Properties

The thermal properties of a metal also impact its performance when working in high-temperature environments.

Some metals, like aluminum, have a high thermal conductivity, but titanium does not. Hence, if heat exchangers for cooling systems are manufactured, then aluminum can be a better choice.

Weight Consideration

Weight is also a major concern in many industries, especially in the automotive and aerospace industries. Hence, the metal should have sufficient strength and a limited weight. Magnesium and titanium are the lightest metals.

Corrosion Resistance

The corrosion resistance of a metal plays a crucial role in many harsh environments. Metals are opted for by examining the environment to which they will be subjected.

Manufacturing and Processing

The processing technique will also determine the material selection; some metals are usable for casting, and some are suitable for CNC machining. Hence, when selecting lightweight metals, their compatibility with the processing method is essential.

Cost

Cost consideration plays a crucial role in materials selection. Titanium, although it is one of the best-performing materials, is expensive. Hence, based on the application requirement and budget, different alternatives are selected.

Other Alternatives to Lightweight Metal

Lightweight metals do have some alternatives that can be opted for instead of the metals, and these are discussed below:

Composites

Composites are manufactured by combining different materials with different chemical and physical properties. Such materials have high strength and are lightweight. Some of the composites are even lighter than metals and have superior strength, which makes them suitable for use and customization.

Carbon Fiber

Carbon fiber is a polymer consisting of filaments of carbon in crystalline form. It has a very high strength and less weight. It is stronger than steel and offers excellent corrosion resistance.

Conclusion

Understanding every detail about lightweight metals is very important when opting for them in projects.

If you are also looking to have lightweight metals processed for your applications, we at DEK can help you. We have a wide range of metal selections and versatile processing capabilities.

FAQs

1. Why choose lightweight metals for your projects?

Lightweight metals offer fuel efficiency, enhance performance, and even reduce payload capacity in applications.

2. Can titanium rust?

No, titanium does not rust or corrode when subjected to harsh exposure.

3. In what way do lightweight materials affect part design?

Lightweight materials offer innovative designs and complex shapes, enhancing design flexibility.

4. Is titanium lighter than aluminum?

No, aluminum is lighter than titanium, but titanium is more powerful.

Welding is a commonly adopted method used for joining components. There are different types of welding methods, and among them, TIG welding is also very commonly selected.

This guide features a detailed insight into what is TIG welding, how it works, and how it differs from other weldings. So, let's read.

What is TIG Welding?

TIG welding is a method of joining metal components by a process that uses electricity. It melts the metal and joins the pieces together. It offers a versatile process that can be opted with different metals and creates very clean and finished welds.

How Does it Work?

TIG welding welds the metal components using a tungsten electrode, which is present in the torch. This torch creates a high-temperature arc, which helps in melting the metal and creates a pool of weld.

TIG welding also uses a filler metal and ensures a very strong joint. It uses non-reactive shielding gas, which helps protect the electrode and the component from rust and corrosion.

The gas is present in the cylinder, which flows and creates the arc using the TIG torch. It even has a power source, which is opted for using a foot pedal to control the current.

Advantages of TIG Welding

TIG welding has many advantages, and some of these are discussed below:

• TIG is a clean method that produces fewer sparks and smoke and, therefore, doesn't need any finishing.
• TIG welding helps to weld components using different positions.
• It offers a high level of control on the arc, and hence, very clean welds are achieved.
• It creates welds that are ductile and have strength. Moreover, they even offer high corrosion resistance.

Disadvantages of TIG Welding

TIG welding also has some disadvantages, which are as follows:

• TIG welding requires skills so that proper control can be exercised.
• The process of TIG welding is slow.
• It requires completely removing rust from the component.
• TIG welding doesn't work with materials that are very thick.
• In order to achieve the right welds, TIG welding requires maintaining the flow of gas constantly over the weld pool.
• It is expensive compared to the traditional welding methods.

TIG Welding vs. MIG Welding

TIG welding and MIG welding differ in many ways. MIG welding has a consumable electrode that can multiply the weld filter twice. The TIG electrode creates an arc, and when you need filler metal, you can add a hand-held filler.

TIG welding also takes more time compared to MIG and requires expert skills, which makes it expensive.

Materials Used in TIG Welding

TIG welding uses aluminum, stainless steel, and nickel alloys, mostly because it is suitable for thinner materials.

Apart from these, TIG can also help weld magnesium, iron, and copper, but it requires preparing these materials by using helium, pre-heating the material, and pre-cleaning it.

Practical Tips for TIG Welding

By considering the tips below for TIG welding, you can attain high-quality welds.

• The torch, when positioned at a forward angle, prevents the air pocket buildup, which makes the bead porous.
• A narrow and short arc length gives more control over welding.
• To keep consistency in the bead, a consistent travel speed is required.
• The weld pool must not be touched with the tungsten electrode.
• The size of the filler metal requires critical control.
• The tungsten electrode tip’s shape must be checked and sharpened using a grinding wheel.

Applications for TIG Welding

TIG welding is used very commonly in different applications, and some of these are as follows:

Aerospace Industry

TIG welding is used in the aerospace industry due to the ability of this process to weld materials that are thin in a precise way. It is suitable for aircraft frames, engine components, and fuel tanks.

Automobile Industry

TIG welding is also used in the automobile sector and welds aluminum and stainless steel components used in fuel lines and exhaust systems of the car.

Repair and Maintenance

Many damaged parts like structural components and the parts of machinery may require repairing which is carried out by TIG welding.

Decorative Applications

Craftsmen also use TIG welding to create decorative items and metal arts, as it helps to create clean welds.

Marine Industry

The marine industry uses TIG welding to weld the stainless steel and aluminum components consisting of frames, hulls, and tanks.

Conclusion

Going through the TIG welding guide above, you must have learned everything about it that you were searching for.

Now, when it comes to having hands-on high-quality components welded through TIG welding, you can get in touch with DEK. We offer accurate, neatly finished, and durable welds through TIG welding.

FAQs

When is TIG welding better than MIG welding?

TIG welding is better than MIG welding when it is used for architectural applications or automobile components. It creates very well-finished welds and does not require surface finishing. Moreover, it also has a low heat input and hence, the structure of the metals is preserved.

Why is TIG welding used for stainless steel?

Stainless steel is usually opted for applications that require aesthetics to be maintained and hence TIG welding can help here by creating neat welds.

Will TIG welding warp sheet metal?

Sheet metal is subjected to warping in almost all types of welding processes. However, if the welder is skilled and controls the amp rate of the TIG welding, the chances of warping can be minimized.

Does TIG welding require gas?

Yes, TIG welding uses inert gas and a non-consumable tungsten electrode to create welds.

Washers are used in conjunction with the fasteners to help fit the components together. The washers are of different types, and each type has a unique purpose. Different materials are used to manufacture these washers.

If you want to learn about the different types of washers, read the guide below.

What are Washers?

Washers are small, flat, and round disc-like components that have a hole in the center. They can be manufactured using different materials and can spread the load over a wider surface area.

The washer is placed between the screw and the surface so that it can help minimize the vibration and act as a spacer. It helps to allow the machine or equipment to function properly and even helps prevent corrosion.

Purpose of a Washer

There are many reasons that may compel you to opt for a washer, such as fitting it with the components in the equipment, machines, and other applications.

Some of the purposes of having these washers are as follows:

• Washers are used as spacers with thread fasteners, which, when inserted in objects, are longer than the depth. The fastener protrudes from the back of the object, and the washers hold it in place.
• Washers help with load distribution through the surface, and the risk of damage and deformation is reduced.
• Washers even control the flow of water and other liquids to enter or exit from the pipelines and connectors. It helps to make a waterproof seal.
• The vibration in some machines and applications is controlled by washers. The washers used are made of materials like plastic, which are soft materials that absorb vibrations better.
• Washers also serve as a protective barrier between the bolt heads and nuts. They help to connect the surfaces by preserving them from dents and scratches.
• They are made using materials that are corrosion-resistant and hence are able to perform in environments that are chemically and moisture-exposed. Hence, they protect the fastening system from corrosion.

Different Types of Washers

There are different types of washers, each having a different purpose; some of the common types are discussed below.

Plain Washers

Plain washers are very commonly used, and they protect the item which is attached to the screw by dispersing force. It even helps the screw to fit properly in a large hole. The different types of washers in the category of plain washers are as follows:

Torque Washers

Torque washers are used in the woodworking sector. The outer prongs of the washer have a hole in a square shape, which keeps the bolt away from spinning.

Flat Washers

Flat washers consist of holes in the middle and have a flat disc-like shape. These are suitable for the screws having small heads so that the weight can easily spread across the wide area.

Fender Washers

The fender washers have a big size with a small hole in the middle. These washers spread the load across a broad region. They mostly opted for the plumbing, automobile, and manufacturing industries.

Finishing or Countersunk Washers

Countersunk washers are meant to secure a countersunk screw having a flat head which creates a flush finish.

Shoulder Washers

Shoulder washers can be made using metals, nylon, fiberglass, and even PTFE. These have a shape like shoulders and work like insulators for wires and screws.

C-washer

A C-washer looks like a flat washer but has a hole cut from the center, which creates a C-shape. The major advantage of these washers is that you can easily modify, remove, or adjust them without removing fasteners.

Spring Washers

Spring washers are suitable for such machines that keep on vibrating during the process of operation.

These washers help to ensure that the fasteners stay in their position by vibrating along with the machine and ensuring their flexibility. Some of the spring washers are given below.

Belleville or Conical Washers

Conical washers are meant to maintain tension during the contraction and expansion of the assembly. They can handle larger weights.

Dome Spring Washers

The dome washer is known for managing larger capacity with negligible deflection. They can absorb vibrations and have curves that can handle the load, offering versatile applications.

Wave Spring Washers

Wave spring washers have curves that work like spacers or cushions. These wave spring washers can support moderate load and offer protection against wear on the surface.

Finger Spring Washers

The finger spring washer has three flanges in a curved layout, which helps to reduce vibration and controls wear and tear and even noise on the rotating components. These washers are mostly made of carbon steel and can handle heavy loads.

Crescent Spring Washers

The crescent spring washer has a curved layout, which helps it maintain flexibility. These washers have a wide deflection range and can handle very light loads.

Lock Washers

Lock washers are meant to prevent the nuts and screws from rotating and loading their position. It helps them stay intact during excessive vibration. Some of the types of lock washers used are as follows:

Split Lock Washers

The split lock washer is also known as a helical washer and helps in securing fasteners. These washers have rings that are bent in opposite directions, inwards as well as outwards. They help to secure the bent by digging into the mating surface.

External Tooth Lock Washers

The external tooth lock washer has a teeth-like structure which keeps the screw head and nut intact. They have a large head with screws and have teeth on the outer diameter to create compression resistance.

Internal Tooth Lock Washers

The inner diameter of the internal tooth locker has many teeth, which keeps the nut head and bolt from loosening. They help dampen noise and lock fasteners in their position.

Specialized Washers

There are different types of specialized washers, which are discussed below

Keps Nuts

Keps nuts are also known as k-lock nuts, which have washers built within them to help with spinning. These washers make the assembly process more convenient.

Top Hat Washers

Top hat washers are suitable when installing or repairing a tap as they are used in plumbing applications.

Keyed Washers

Keyed washers are used to facilitate the bolts so that they can be prevented from spinning. These washers are mostly used in the automobile industry.

Insulating Shoulder Washers

Insulating shoulder washers are made using plastic, peek, or nylon and are used in electronic applications. These washers help in the solution of mounting screws from electric current.

Gaskets

Gaskets are also known as o-rings; they are made of rubber and have multiple sizes to fit each purpose.

These are mechanical seals that can fill the space between surfaces so that spills and leaks can be prevented. Gaskets are used in automobile sectors to prevent the gas and oil connectors from leaking.

Materials Used to Make a Washer

Washers offer versatility in materials, and hence, there are different types of materials used for manufacturing them. Some of these are as follows:

Nylon and Rubber

Rubber washers are made with synthetic rubber nitrite, which helps seal the washers. Nylon also offers the same properties. These washers offer improved flexibility, but districts are under pressure.

Metal Washers

Metal washers are made using different types of metals and grades and offer excellent properties.

They are powerful; hence, the seal is quite strong, ensuring that there are no leaks or drippings. The metal washers are mostly made with stainless steel ensuring resistance against corrosion.

Plastic Washers

The plastic washers are manufactured using injection molding and offer cost-effectiveness. These are adopted due to the strength they offer and also are suitable for electrical isolation and resisting vibrations.

Plastic washers are suitable for electronic applications and can be either as clear plastics or different colored plastics.

Size Chart of Different Washers

SAE and USS are two different types of size charts used by machinists for washers. The charts for the size guide are given below.

Washers Standards You Need to Know

The washer standards which are important to know when opting for washers are as follows:

ASME ANSI B 18.22.1 Plain Washers

The ASTM F844 standard covers the flat washer inches series, which are commonly used. The flat washers have a bearing surface and are used under applications using either bolt heads or fasteners having external threads like bolts.

ASME B18.21.1 Helical Spring-Lock Washers

Spring lock washers from the inch series have heavy-duty varieties and are made with stainless steel or spring steel.

These are used in applications where the load has to be distributed over a large area to create a surface with a hardened bearing. It facilitates the assembling of components.

DIN 125A Flat Washers

Flat washers under the DIN 125A are made using sheet metal and have a smooth surface with a bearing. The flat washers go underneath the heads of bolts and nuts and are made using carbon and stainless steel.

DIN 6799 Retaining Washers

Retaining washers are high-performance washers, which are also called E-rings. They use eccentric shafts with grooves to support spring retention and are suitable for axial force transmission.

What are the Shapes of Washers?

There are different shapes of washers that are utilized in various applications, and these are discussed below:

Spherical Shape

Spherical shape washers have a parallel plane between the bolt head and nut face. These washers can balance the misalignment between the planes and protect them against bolt bending.

Some examples of such shaped washers are flat washers, slotted, countersunk, and fender washers.

Square Shape

Compared to round washers, square washers offer a wider surface area, which enhances the distribution of torque. It offers rotation prevention and even ensures corrosion resistance.

These are meant to restrict vibration, noise, and electric current. These washers are mostly countersunk, flat, or structural washers.

Shoulder Shape

Shoulder-shaped washers are also called insulator washers. These are made using nylon, and they have a barrel that is either long or short; they protect the fasteners from dirt and moisture.

Wave Shape

Wave-shape washers are metal-based washers that are covered in two different directions and are opted for as cushions and spacers. They can handle the load, maintaining tension even when compressed. A wave washer is an example of a wave shape.

C-Shaped

C-shaped washers are designed to be slid in and out on a bolt and do not require loosening. C-washers are used for retention on the grooved shaft, and they keep the components in their position.

Some of the examples of these washers are slotted and lock washers.

How to Choose the Right Washer?

The selection of the right washer is very crucial to achieving the required purpose, and some of the considerations to have in mind when choosing one are the following:

Material Type

Material is the first consideration when choosing the washer, and in this case, you need to assess the strength.

When choosing a washer, the base material and the washer material must have the same strength. In cases where the strength is not compatible with one another, the base material may be damaged.

Bolt Strength and Washer Strength Compatibility

The bolt and washer type should be matched. The high-strength bolts must be used with high-strength washers so that the stability of the product is obtained.

Bolted components must have matching material; for instance, metal bolts should have metal washers, and plastic bolt nuts should have plastic washers.

Environmental Considerations

The environmental conditions in which the washer will be used are also assessed when selecting it.

If the washer is exposed to harsh chemicals and weather, the material of the washer selected should be resistant to corrosion and durable enough to handle such exposure.

DEK Meets Your Specific Washer Needs

As you have gone through the extensive guide above, you must have understood the significance of choosing the right washer.

You can connect with us at DEK if you are looking to have custom washers designed for your new project. We offer high-quality and versatile material suggestions followed by an excellent surface finish.

Conclusion

Washers are used in many applications ranging from plumbing to aerospace, and their criticality also varies based on the application requirements.

Hence, it is always crucial to select the right washer type, material, size, and standard for washers, as discussed in the guide above.

FAQs

How do you use washers quickly?

You can screw the bolt in the washer and insert the washer and bolt together in the mounting hole. You can now twist the bolt head using a wrench.

Why do we use washers with screws?

Washer screws help in sharing the weight, and when used without screws, it can lead to damage to the surface of the bearing.

What’s the difference between spring washers and flat washers?

Spring washers are plain, flat, and curved washers and are widely used in many applications. Spring washers are used to prevent vibrations.

In mechanical engineering, the tolerance fit is the allowed deviation from the assigned one for the components.

The guide below discusses everything about tolerance press fit and how it is considered in different applications. So, let's take a look.

Understanding Tolerance Press Fit

A tolerance press fit is a deviation that is allowed compared to the nominal dimensions. It ensures that the parts can be connected with one another without any compromise on the joining integrity.

Press fits are dependent on the systems like shaft or hole basis, which defines the limit when the hole is smaller than the shaft.

Assembly is achieved with the help of hydraulic or mechanical presses, making the precise tolerance controlled so that damage on the part can be avoided.

Why is Tolerance in Press Fits Important?

Manufacturing processes have the chance of inaccuracy, and the role played by tolerances is very important. It determines the minimum and maximum limit for the parts. Hence, tolerance in fit ensures that the parts fit with one another smoothly and tightly.

It also ensures that the press-fit assembly works with proper functioning. Tolerance in press fits provides the capacity to carry the load and ensures enhanced alignment and strength.

Pros of Using Press Fits

The benefits of using press fits are discussed below:

• It provides you with a strong and good clinch that can accommodate heavy loads and is used in applications where high stress persists.
• Press fits eliminate the need to use fasteners, which saves cost and time during the process of assembling and manufacturing.
• Press fits create a stiff connection, which reduces vibrations and is suitable for applications that work with dynamic loads.
• It ensures that the components that are assembled have accurate fitting and alignment and there is not even a minor variance.
• A permanent bond is created using press fit if no disassembling is required.
• The press fits are compatible with many materials like plastics and metals.

How do Press Fits Work?

Press fit works on the interference principle and is commonly used when a shaft is being fitted with a hole. When the two components are pressed together, the interference creates fiction, which fixes the two components firmly.

The component material may deform during the process of assembly to create tight bonds. The main aim is that parts stay connected.

Press fits have to be highly accurate and precise; hence, choosing the correct shaft and hole parameters is essential. The difference between sizes is measured in microns.

The pressure required to press components together is based on the amount of interference. The material type and design influence it. A proper fit creates a durable connection.

Types of Tolerance Press Fits

There are different types of tolerance press fits; some are given below.

Interference Fit

Interference fit has the shaft size greater than the hole size and creates the toughest press fit. It has a high frictional force. It is used in applications where the components need to remain assembled.

Transition Fit

A transition fit is a type of press fit that is in between the interference and clearance fit. It is a light interface fit and is used in applications where separation is required.

Clearance Fit

Clearance fit is the one that has a hole larger than the shaft, which makes it easy to assemble and disassemble. This type of press fit is used in components that need to be moved.

Key Factors Influencing Tolerance in Press Fits

Some of the factors that influence the tolerance in press fits are as follows:

Material Properties

Press fit performance depends on the materials you choose. The material properties are important to consider here, like elasticity, thermal expansion coefficients and hardness.

For instance, aluminum is softer than other materials and needs care when it comes to machining compared to other types of hard metals.

Temperature Variations

Changes in temperature may cause expansion and contraction in the materials. High temperatures significantly impact the tolerance of the components.

Lubrication

Lubrication is essential for minimizing friction in situations where galling is an issue. However, lubrication should also be done carefully to ensure a proper fit.

Assembly Method

The method of assembling impacts the press fit quality. The hydraulic press exerts an even and controlled force, which ensures firm assembling.

Component Geometry

The size and shape of the component also determine the press fit. The geometry of the component should have the right interference amount.

Press Fit Standards

Press fit needs to be accurate and consistent, and hence, some industry standards set the tolerance limits. These standards are as follows:

• ISO 286 is an international standard that deals with the press fit classes and the limits that are allowable for the size of components.
• ANSI B4 1 is an American standard that offers multiple cases for fit and tolerance, and you can choose the desired interference level.
• DIN standards are German standards that look into the tolerances and press fit to ensure that the designs match the stipulated precision levels.

Measuring and Calculating Tolerance for Press Fit

The process of calculating and measuring tolerance for press fit is discussed below.

Tools and Techniques for Accurate Measurement

Some of the tools and techniques for accurate measurement of the press fit are as follows:

Coordinate Measuring Machine: It is a high-precision tool that measures the tolerance and dimensions of the interference fit.

Plug Gauges and Gauges: These are used for measuring the tolerance of holes.

Calipers and Micrometres: These are accurate design readings for the press-fit components, such as diameters, lengths, and depths.

Optical Measuring Systems: These systems have high-end cameras that process algorithms for measuring sizes of the press fit.

Some of the techniques for the measurement of the press fits are as follows:

Ultrasonic Thickness: The ultrasonic systems are used for measuring the material thickness which identifies the changes in components during the assembling process.

Inferomtery: The interferometric technique uses the interference patterns of the light waves and measures the distances using high precision.

CT Scanning: It is a method that inspects the internal part of the press fit assembly for checking the misalignments.

Tolerance Press Fit Chart

How to Give Tolerance in a Press Fit?

In order to give tolerance in a press fit, the first thing is to determine the type of fit, whether it is light, heavy, or medium, based on its purpose of use. In between the hole basis system and shaft basis system, one of the systems is chosen.

The required interference is then calculated based on the material properties, standards, operational factors, etc. The range of interference is mostly between 0.01mm to 0.1mm.

Once tolerances are denied, the shaft and hole are machined to the dimension and are inspected using different tools for measurement.

Challenges in Achieving Optimal Tolerance

Some of the challenges in achieving the optimal tolerance in press fits are discussed below.

• The measurement tools are very important to be accurate, but due to less accuracy in them, the achievement of optimal tolerance in the press fit is challenging. It may result in an inaccurate assessment of dimensions. It is important to use tools that are highly precise.
• In case of poor material analysis, some unexpected challenges may occur. Material properties must be analyzed thoroughly by proper testing.
• Due to inadequate tolerance analysis, the interference may have unpredictable behavior. Make sure to reduce tolerance accumulation in an efficient way to attain optimal tolerance in the press fits.
• During the manufacturing process, the lack of control also causes difficulty in achieving the optimal press fit tolerance. Make sure to implement a strict control process during the manufacturing process.

Common Applications of Press Fits

Some common applications of press fits are discussed below:

Automobile

In automobile manufacturing, the tolerance press fits are used in engine components, bearings and wheels. The camshafts are press-fitted in the bearing so that they won’t have trouble connecting.

Aerospace

Tolerance press fits are important in aerospace as they can be used in landing gears, turbine blades, and structural parts. These fits ensure that the components stay intact during the operation of the aircraft.

Medical Equipment

Medical devices also need tolerance press fits, as reliability and accuracy are very crucial in this field. The connection between implants and surgical instruments requires press fits.

Best Practices for Tolerance in Press Fit Design

In order to achieve precise tolerance in press fit design, the following tips can be utilized:

• Select the materials that have compatibility of hardness, elasticity, and also matching thermal properties so that the interference fits have tight tolerance.
• Analyze the tolerance stack-up to assess how the tolerances of individual components will interact and how they will perform collectively.
• The design of the components must be matched with one another to ensure that the interference fits with the required application.
• Choose materials that can suit the environmental condition of the applications where the press-fit designs will be used.
• Ensure having surface finishes that help mitigate the friction and help maintain the required tolerance.

Differences between Press Fit and Slip Fit

Press fit and slip fit are both methods of joining the components, but they do have some differences, which are as follows:

• Press fits consist of using an interference measurement to ensure that the connections are created with strength. Slip fit allows for a clearance measure for ease of assembly and disassembling.
• In press fit, you have to use force to bring the parts together, whereas in slip fit, the components slide together with negligible force.
• Press fit produces a high amount of interference, which creates frictional force, leading to a good fit. Slip fit has low friction and the assembling is loose.
• Press fit is mostly opted for applications that are either semi-permanent. Slip fits are used in applications where the parts require removing or altering.

Conclusion

The depth of the subject of press fit tolerance can be analyzed from the guide above, it is very crucial to understand it so that you can always come up with accurate press fits.

We at DEK can design highly precise press fits component for your projects based on the application requirements. We have all types of tools, machines, and measurement analysis that help us manufacture press fits parts with high accuracy.

Precision machining is the backbone of the manufacturing industry.

It has various machining processes– among which boring machining also plays a vital role. It is a machining process that caters to multiple applications.

If you are inclined to learn more about boring machining, you can read the guide below.

What is Boring Machining?

Boring machining is a precise process that enlarges the holes that are already drilled in components.

The main purpose of considering machining is to make the holes meet the specific requirements of surface finishing and dimensions.

It consists of a tool that rotates and widens the hole, making it highly accurate and smooth.

Boring machining was invented in the 18th century by John Wilkinson, who invented it in 1774 to manufacture blocks in cylindrical shapes for steam engines.

As time passed on, advancements followed in 1860; Francis A Pratt’s machine was innovated, which used a screw feed manually.

Even during the world wars, jig borers were invented, and in the 1970s, CNC machines were all over, taking the place of mechanical systems. The boring machine was then controlled by a computer.

The Advantages of Boring Machining

The boring machining process has a wide range of advantages, and some of these are as follows:

• Boring machining is a highly accurate process and helps to create holes in different materials that are not achievable by drilling.
• This process even helps to achieve the finest surface finishing, which can create a surface finish that is up to 32 micro inches.
• Boring machining is a versatile process, and it is compatible with a wide range of materials, such as aluminum, steel, plastic, and wood. It can enlarge not only round holes but also keyways, slots, and grooves.
• Boring machining gives you an opportunity to create holes of customized sizes and is crucial in applications that require high precision.
• The automated boring machines are quick, and hence, the time needed to create the enlargements in holes is less, which makes them efficient. Hence, it proves to be suitable for high-volume applications.

The Disadvantages of Boring Machining

Boring machining also has some downsides which cannot be ignored, and these are as follows:

• The cost of equipment is high, and it cannot be justifiable for a small business or a project that has a small volume.
• Boring machining requires skills for operation; hence, to achieve efficiency and accuracy, you must invest in labor training.
• It can only enlarge the holes that already exist and cannot drill fresh holes.
• When the hole is too deep, the risk of tool deflection is present, especially when the boring bar lacks rigidity.

How Does Boring Machining Work?

The working mechanism of boring machining is given as follows:

• The process uses a CNC milling machine or a lathe and a tool called a boring bar, which is fixed with a cutting insert.
• A hole is first made by drilling.
• In the pre-drilled hole, the boring bar is inserted, and the lathe rotates the workpiece. At the same time, the boring tool is stationary and trims the inner edges of the hole. The hole is then enlarged.
• The process continues unless the required surface finish and dimensions are achieved.

Types of Boring Machines

There are different types of boring machines, and these are as follows:

Vertical Boring Machines

A vertical boring machine carries out the boring task in a vertical direction.

The workpiece on which the boring has to take place is placed on a rotary table, and the boring tool cuts from top to bottom. Vertical boring machines are suitable for heavy and large components.

Horizontal Boring Machines

A horizontal boring machine is designed to bore holes horizontally. It has a spindle aligned horizontally and holds the boring tool. This machine is suitable for larger components that require precise boring.

Precision Boring Machines

Precision boring machines are meant specifically for boring and have a size smaller than milling machines and lathes. They are highly suitable for small components and offer excellent surface finishing.

Table Type Boring Machines

A table-type boring machining tool can bore holes in the horizontal direction, but it is small and mounted on a table.

Floor Boring Machines

Floor boring machine is a large machine that can bore massive components. The component is placed on the floors, and the boring tool is fixed on the moveable column.

It is very commonly used in heavy duty industries like manufacturing larger equipment and shipbuilding.

Applications of Boring Machining

The boring machining process offers to manufacture components for multiple industries, and some of these are discussed below:

Automobile

In the automobile industry, boring machining creates bores in engine blocks and cylinders which helps to enhance the efficiency and performance of engines.

Aerospace

The aerospace industry uses the process of boring machines for its components, like landing gears and turbine casings, with accurate dimensions.

Construction

The construction industry requires creating large holes in concrete to cater to infrastructure projects, and hence, boring machining is widely opted for.

Oil and Gas

Components in the oil and gas industry, like pump housing and valve bodies, need exact dimensions to be bored, and the oil and gas industry caters to them.

Challenges for Boring Machining

Boring machining is a challenging process, and some of the challenges encountered in this process are as follows:

• When the process of boring is done, the presence of friction may result in wear and tear or tool, which impacts the performance of the machine.
• Machining errors experienced while boring machining may alter the dimensions, location, and surface finish of the holes.
• Sometimes, the components after boring machining may have a lack of surface finishes like lines on the components, which is due to the incorrect feed rate.
• Measurement error is a major challenge in boring machining. If inappropriate tools are used or incorrect measurements are entered, the results are not accurate.

Practical Tips for Boring Machining

Boring machining processes can enhance the optimal results if the following tips are considered during the process:

• Keep a check on the tool wear, replace the damaged cutters, and ensure that the clamps hold the tool tightly during the machining process.
• Ensure that coolants are used during boring machining so that heat can be managed, and it even helps reduce friction.
• Measure the diameter of the hole using a caliper and, based on that, calculate the machining allowance.
• Keep an allowance of 0.3 to 0.5 on the boring tool, and for roughness, make sure that the allowance is not less than 0.5mm.

Boring vs. Other Machining Methods

There are various processes that can be considered to compare with the boring machining process, and these are as follows:

Boring vs. Drilling

Boring and drilling are both processes that remove material. Drilling, however, creates a hole in the workpiece, but boring improves the hole by enlarging it.

Drilling doesn't offer the surface finish that is offered by boring. The holes created by drill are narrow, whereas the ones created by boring are wide.

Boring vs. Turning

Turning is also a process that removes material from the workpiece. Boring has a single tool for cutting, which has a pointed head, whereas turning has a cutting tool that does not rotate and removes external materials.

The main difference between both is that turning works on the external surface, whereas boring works on the internal surface.

Boring vs. Reaming

Reaming and boring are both cutting processes and removing the material from the internal part of the component.

However, the process of boring consists of a tool that has a single pointed head, and the reaming uses cutters that rotate and cut the material.

They both work on holes that are pre-drilled. The main difference lies in the application process; boring broadens the hole and creates a smooth internal wall.

Conclusion

Boring machining is used for a lot of applications and components, as you must have understood in the guide above.

If you are seeking a reliable service partner that offers you high-quality components with bored holes, you can get in touch with DEK. We have specialized machinery and trained labor for boring machining services.

FAQs

What is the purpose of boring?

The main purpose of boring is to enlarge pre-drilled holes and improve their surface finish.

What are examples of boring tools?

There are different types of boring tools, such as starter drills, boring bars, and boring drills.

What types of materials can be effectively machined using boring machining?

The process of machining is highly versatile and can be chosen for materials which include metals, plastics, and even wood.

CNC engraving is a popular CNC process used by industries to create patterns on their components.

If you are confused about what CNC engraving is and are eager to learn, this guide below will tell you everything. So let's read.

What is CNC Engraving?

The process of engraving removes the material from the component in a very controlled way and creates marks and patterns on the surface of the material.

CNC engraving is an automated and highly precise method to engrave any component with accuracy.

Engraving can cater to multiple industries which include sign-making as well as decor. The best part is that it is highly compatible with most of the materials. CNC engraving is also an affordable form of machining.

How CNC Engraving Works?

CNC engraving works in a step-by-step manner that involves essential techniques. The section below features a detailed engraving technique.

• The designers initially create a digital design to be engraved on the CAD software as this software is capable of creating complex patterns.
• The CAD design is then converted into a CAM design, which generates the G-code file containing instructions for the CNC machine.
• The CNC machine is then prepared with a workpiece placed perfectly so that the process may take place smoothly.
• The process of CNC engraving is an entirely automated procedure; once completed, the workpiece is released.

Types of CNC Engraving

CNC engraving is of different types, and the three most common types of CNC engraving are as follows:

CNC Laser Engraving

CNC laser engraving is a process in which a high laser beam is used to heat the workpiece so that sublimation takes place. Once the workpiece is heated, the laser head moves with a CNC-controlled machine and creates the pattern.

CNC Rotary Engraving

CNC rotary engraving has a rotating tool that removes material from the workpiece.

The cutting edges of the tool have a flute-type shape, and with the help of its sharp edges, it cuts the material. The size and shape of the cutter are very important to attain the required pattern.

Diamond Drag Engraving

Diamond drag engraving is a process that has a diamond tip, and it moves with the CNC machine.

Diamonds are one of the hardest metals and, hence, offer an efficient engraving process. It offers high precision and accuracy and can work with the hardest metals.

Common Materials Used for Engraving Machining

CNC engraving is carried out on various materials, a versatile process. Some of the commonly used materials in the process of CNC engraving are as follows:

Metals

Metals are very commonly used in all types of CNC machining processes, and the same goes for CNC engraving.

Different types of metal are used in CNC engraving, including gold, copper, brass, stainless steel, aluminum, etc. However, when choosing metals for CNC engraving, the tools selected should be hard enough.

Plastics

Plastics also opt for CNC engraving, and plastics have multiple types of polymers that work perfectly with CNC engraving.

Thermoplastics are, however, commonly selected as they offer thermal stability. They can be compatible with rotary and CNC laser engraving.

Some of the types of plastics are nylon, ABS, polyethylene, polystyrene, polyurethane, etc.

Wood

Wood engraving is used for decorative items and luxury products. It is the softest and cheapest option when it comes to manufacturing engraved components.

It can work with CNC lasers as well as rotary engraving machines. The different types of woods that can be chosen for CNC engraving are balsa, softwood, cork, and hardwood.

Pros and Cons of CNC Engraving

CNC engraving has various pros and cons, and some of these are as follows:

Pros

• CNC engraving is a highly precise and accurate process, and when it engraves the component, the accuracy is commendable hence, sensitive applications may find it to be suitable.
• CNC engraving helps to save time compared to the manual engraving process. It is automated and quick, and the results are excellent.
• When CNC engraving is opted for, custom designs are allowed to be manufactured for custom components.

Cons

• CNC engraving requires a high investment, and if the process is carried out for a low volume of components, it can be expensive.
• The thickness of the material is a concern, and the process must be compatible with a certain thickness level to attain the best results.
• CNC engraving machines can be operated by trained and experienced people; hence, training is a must to operate them efficiently.

Applications of CNC Engraving

The applications of CNC engraving are as follows:

Sign Making

Road signs and some advertisement signs require CNC engraving so that they can withstand different weather conditions.

Jewelry

CNC engraving is used in jewelry making and helps create bracelets and pendants, having personalized texts added with the help of engraving.

Trophies and Awards

Awards and trophies which can have the names of recipients engraved, are quite common. CNC engraving gives an opportunity for these personalized trophies and awards to be engraved.

Conclusion

We at DEK offer you CNC engraving services for your components where you want to add a personalized touch. We work with a wide range of materials composed of metals, plastics and wood.

So, if you need to outsource your CNC engraving project to us, you can get in touch.

FAQs

What is the difference between engraving and etching?

Etching and engraving are the two processes in which material is removed from a component, but they have different processing methods. Engraving uses cutting tools, and etching uses chemicals to burn the surface of the material.

How does CNC engraving differ from laser engraving?

In the process of laser engraving, a laser melts the material for engraving. On the other hand, CNC engraving uses digital techniques for controlling the cutting tool.

Which software is used in a CNC engraving machine?

CNC engraving machines use CAD/CAM software, which helps perform engraving tasks using cutting parameters and tools after selection.

What cutters or bits are needed for CNC engraving?

CNC engraving uses bits and cutters that are the same as those used in usual CNC machines. The common types of cutters are carbide tips and diamond tips for harder materials.

Alloys are widely used in different components due to their exceptional properties. Kovar is also a widely used alloy, primarily featured in sensitive technological applications.

Let's dive into the guide below to learn about Kovar machining process and its pros and cons.

What is Kovar Alloy?

Kovar is an iron, nickel, and cobalt alloy invented in the 20th century. It is a silver-gray metal with low thermal expansion, similar to ceramics and glass.

Kovar is a very important material used in different components that need tighter tolerance. It is used in versatile industries like medical, aerospace, and electronics.

Pros of Machining Kovar

Kovar comes with various properties that offer significant advantages; some of these advantages are as follows:

• Kovar has exceptional thermal stability and low thermal coefficient. Hence, it can be used in applications that have consistent temperature changes and can withstand them without cracks and breaking.
• It has a high yield and tensile strength, which makes it suitable for high-stress applications. It can easily withstand the pressure without deforming.
• Kovar offers durability and can easily be subjected to harsh environments, and it can resist oxidation, chemicals, and corrosion.
• Kovar is a versatile material and is highly machinable, which helps manufacture components in complex shapes.

Cons of Machining Kovar

Along with advantages, Kovar machining also has some downsides, and these are as follows:

• The material is expensive and, therefore, is mostly not considered when high-volume manufacturing is required.
• It's very rarely available, and securing it is a challenging task.
• Kovar is brittle and can fracture due to sudden shocks.
• It is difficult to work with and needs specialized equipment and expertise to manufacture components of high quality using it.

Typical Processes for Machining Kovar Parts

Kovar machining can be done through various processes based on the application and component requirement. Some of these processes are as follows:

CNC Milling

CNC milling uses Kovar to manufacture complex components. The hardness of Kovar requires selecting the right cutting tools and speed to avoid tool wear. Coolants are also needed during milling to ensure precision and prevent tool wear.

CNC Turning

CNC turning is a machining process in which round and cylindrical Kovar components are manufactured. Carbide tools are used for this process, and a moderate cutting speed is maintained to prevent work hardening.

CNC Drilling

CNC drilling is a process in which holes can be created with high precision in Kovar components. The process uses carbide tools with a slow feed rate to prevent tool wear and achieve accurate holes.

EDM

EDM is one of the most effective machining methods for Kovar, helping in creating intricate shapes. It can machine the thin sections of Kovar. Being a non-contact process, it prevents work hardening and deformation of materials.

Laser Cutting

Laser cutting, as the name suggests, uses a beam of laser to create clean cuts on the Kovar component. It is suitable for applications that need components with high tolerance and precision and reduced thermal distribution.

Key Applications of Kovar Alloy Machining

Koval alloy machining is used in multiple industries. Some of the applications of Kovar machining are discussed in the section below.

Glass Sealing

Kovar is machined for vacuum systems to create glass-to-metal seals. Due to its coefficient of thermal expansion matching that of borosilicate glass, it is the most suitable choice for this application.

Electronics

Kovar is used in the electrical industry for transistors, diodes, and other components that need semiconductive features. It has high mechanical strength and hence can offer reliable connectivity.

Aerospace

Kovar alloy can be machined for aerospace components as they have significant temperature changes and tough requirements for sealing, which Kovar meets.

Medical

Machining Kovar helps create components compatible with medical applications. Kovar components offer biocompatibility and are not impacted by temperature changes; hence, they are suitable for implantable devices as well.

Design Considerations When Machining Kovar

When machining Kovar, some design considerations should be followed to achieve the finest quality components, and these are as follows:

• Ensure that the coefficient of thermal expansion of Kovar and the adjacent materials match so that thermal stress can be avoided during machining.
• Machining Kovar needs a slow speed and a high feed rate, so work hardening can be reduced.
• It is suggested that carbide tools be used when machining Kovar to avoid wear and tear.
• In order to ensure dimensional stability in the components made of Kovar, try to conduct pre- and post-annealing on the components.
• You can also opt for a surface treatment after machining Kovar to prevent contamination and oxidation, as well as enhance the component's life.

Challenges in Kovar Alloy CNC Machining

Machining Kovar comes with certain challenges. This section below features those challenges and the solutions that can be implemented to deal with them.

Work Hardening

Work hardening is a common issue during Kovar machining, making it difficult to conduct the process and even impacting the tool's life.

To prevent this issue, it is suggested that the cutting speed be maintained at a low speed and increased lubrication, which helps reduce the heat.

Tool Wear

Kovar is a tough material and can cause tool wear. A carbide tool is suggested, which can withstand the process of machining Kovar and maintain its sharpness in the long run.

Thermal Expansion Management

Kover has controlled thermal expansion, but sometimes, if the machining process is not managed appropriately, it can become problematic.

Always plan the machining process and consider the thermal expansion based on the operating temperature environment.

Surface Oxidation

Kovar can develop a layer of oxide if it is heated. This impacts the quality of the component, and to control this, you can control the speed of machining and manage heating.

Internal Stress

If Kovar components are not annealed, they tend to develop internal stress. Hence, annealing these parts before machining helps relieve internal stress.

Start Your Kovar Machining Project with DEK

If you are looking for a reliable machining partner for Kovar components, DEK can be your go-to choice. We have experience in Kovar machining and hence can offer you fine, precise, and accurate components.

You can discuss your requirements and industrial application with us, and we can design custom Kovar components machined for you.

To Sum Up

Kovar is an alloy that is very rarely used. It is very important to understand everything about it before you decide to use it for your project.

As you have gone through the guide above, you must have learned about Kovar machining and how to deal with the associated challenges.

The world is moving rapidly towards new innovations, and among them, the innovation of drones is also a very good progression.

Custom drone parts are required when it comes to manufacturing drones. The guide below details the processes associated with manufacturing custom drone parts. So, let's read.

Explaining the Drone Parts Manufacturing Industry

The drone parts manufacturing industry is growing rapidly as drones are being used to expand access to different industries. Drones are used in defense, logistics, agriculture, entertainment, and even surveillance.

The advancement of this technology requires meeting the demand for high-quality components. The drone part manufacturing industry is one of the most crucial industries that leads to the manufacture of a complete drone system.

What Technologies Do We Use in UAV & Drone Parts Manufacturing?

Various technologies are used in the process of manufacturing UAVs and drone parts, and some of these are discussed in the section below.

CNC Machining

Precision and accuracy are the foundation of drones, and these can be achieved with appropriate CNC machining methods. CNC machines are used to manufacture complex drone components, such as frames, motor mounts, and other structural parts.

Specifically, 5-axis CNC machining is considered for manufacturing complex and detailed components with excellent accuracy as needed by the drone industry.

The 5-axis machining has the ability to move the cutting tool in 5 different axes, which helps achieve complex geometries. The drone's components, like propeller blades and electronic housing, need a process that meets their machining complexity.

Moreover, the process is compatible with a wide range of materials, including titanium, carbon, and aluminum. So, in less time and setups, 5-axis machining can manufacture components that are highly processed and have complex angles.

3D Printing

3D printing is a process that is used to manufacture lightweight components in drones. It works by adding layers of materials one after the other and creating a 3D component.

It has been used to manufacture prototypes of drone components. The 3D printing process is compatible with metal and plastic. It can manage components like airframes and enclosures in a small quantity.

Sheet Metal Fabrication

The sheet metal fabrication process helps manufacture the components for drones, which need structural strength and durability.

The major method of sheet metal fabrication for drone parts is laser cutting, which helps to cut metal with speed and precision. It can help achieve precise sizes and shapes and is used for manufacturing drone frames and landing gears and brackets.

Laser cutting creates clean and fine edges that can be cut using materials like steel and aluminum used in drones. It offers high precision, less waste, and even quick production.

Injection Molding

Injection molding is a process in which plastic components are manufactured in high volume.

The plastic components used in drones are also manufactured using injection molding. Sample components are sensors, propellers, and camera housings, which are all lightweight.

It uses a wide range of thermoplastics, which offers flexibility, strength, and light weight in the components. It requires creating a mold, and once it is manufactured, the components can also be created with high quality.

Urethane Casting

Urethane casting is an affordable method that can manufacture a limited quantity of components for drones. It is also opted for prototyping and is an alternative to injection molding for a small batch.

Urethane casting uses a master mold, and then urethane resin is poured into it to replicate the master mold. It helps create flexible and lightweight components for drones.

The Importance of CNC Machining in Drone Parts Manufacturing

CNC machining is of high importance in the process of drone parts manufacturing. It offers consistency, accuracy and high precision when manufacturing components for drones.

CNC machining has the ability to work with a wide range of materials, including plastics, metals, and even composites.

It has advanced techniques that help to manufacture custom drone parts with complex shapes like 5-axis CNC machining. Moreover, it is a scalable process that can be used to manufacture high volumes as well as prototypes.

Material Selection for Drone Parts Manufacturing

Drone parts are made using versatile materials, and some of these are as follows:

Carbon Fiber: It is a lightweight, high-strength material suitable for drone frames and fuselages.

Fiberglass: Fiberglass is an affordable and heavier material compared to carbon fiber and is chosen for drone components that are less critical.

Kevlar: It offers high resistance against impact and makes the drone durable in rough conditions.

Thermoplastic: It is a flexible, strong component that helps create parts of drones with precise designs.

Aluminum: It is strong and lightweight and is commonly used in landing gears and drone frames.

Titanium: It offers corrosion resistance and high strength and hence is suitable for high stress drone components and rotor blades.

Magnesium Alloys: They help in reducing the weight of the drone and ensure efficiency.

Copper: It is used for the electric components of drones, such as wiring, ensuring efficient signal and power transmission.

Post-Processing of Drone Parts Manufacturing

Once manufactured using different methods, drone parts also need some post-processing operations, which help to enhance the durability and surface finish.

Some of these post-processing methods used in the drone parts are as follows:

Bead Blasting

The process of bead blasting involves blasting the particles of beads in small sizes on the component at a high speed. It helps to finish and clean the surfaces. It creates a uniform surface, which helps with further processing.

Anodizing

Anodizing is an electromechanical process in which the metal surface is converted into an anodic oxide-based surface, making it corrosion-resistant.

Powder Coating

Powder coating consists of applying dry powder and curing the component under heat to create a durable finish. It can also add color to the component and protect it against environmental damage.

Painting

Painting is a very basic process of surface finishing in which liquid paint is applied to a component, achieving a layer of protection. It enhances the aesthetics of the drone components and even protects them against corrosion.

Applications of Drone Parts Manufacturing

The drone part manufacturing process is featured in various applications, and some of these are as follows:

Monitoring Public Safety

Drones can use thermal imaging and can be used for various safety procedures, such as dealing with forest fires. They can also bypass any natural barriers.

They can scan areas and prioritize targets with high-resolution cameras. They can also offer real-time aerial insights and can be used for mapping accidents and crime scenes. Hence, all in all, they improve the response and safety time.

Industrial Inspection

Industrial drones are used in communication towers, power lines, and wind power inspections. They have sensors that can identify the leakages and can help with timely decision-making.

Even in case of emergency, the drones can assess the damage and help with repairs. They can carry out an inspection of any site from a distance.

Aerial Mapping

Drones are widely used for aerial mapping to survey the land and urban planning. They help collect geographic information and process data so that operational costs can be reduced.

The data created by drones is precise and includes photography, which helps planners visualize everything.

Summary

In the future, the manufacturing of drone parts will focus on using lightweight materials that are energy efficient.

The demand for these drones is increasing in most sectors, and hence, methods that enhance battery life and improve flight efficiency will be considered. Moreover, opting for environment-friendly materials is also important.

Your Trusted Drone Parts Manufacturing Partner - DEK

DEK can be your go-to manufacturer for drone parts. We have been manufacturing custom drone parts and prototypes for a wide clientele and have gained sufficient experience to ensure accuracy and precision.

Our team is experienced and possesses expert knowledge in designing drone components based on the application and industry requirements.