Month: November 2021

Turning a part: using metal stamping kit and solving the problem

I am often asked about the secrets of making metal stamping kit. Turning process of a part despite having many years of experience as a turner, this question baffles me.

You cannot answer with one sentence, and I don’t want to turn the dialogue into a scientific treatise. In the turning business, many different operations are practiced, so for now we will focus only on turning.

Parts that are difficult or impossible to make by stamping or welding are made on lathes by machining. The advantage of turned parts is their ability to withstand high pressure.

How to choose metal stamping kit?

Everyone knows that there are different brands of metal in metal stamping kit. For novice operators, I can give a general recommendation: choose the cutting mode and the amount of removal with an eye not on the grade, but on the way it is machined.

Further, you will not change the composition of the metal: you have to work with what you have. But such parameters as annealing, nit riding, carburizing and hardening, tempering or stress relief, the turner can easily control.

Depending on the task at hand, we machine specific areas of the part. I would like to draw the attention of operators to the problem of tightening the metal stamping kit during part turning, in particular when processing the outer diameter of the work piece,

Smart tips for easy work

So, let's talk about how to surprise, not only customers, but also ourselves with our work.

• Turned pipeline parts to ensure rigidity; regularly check the bolts and nuts, which should be tight to the maximum
• Know when to stop and do not rip off the bolts, otherwise you will not be able to readjust the machine
• Always adhere to the stock removal rates, cutting speed and feed rates indicated in the standard tables
• Do not use deformed stamping kits or stripped-off thread hold-down bolts.
• Change plates in time. Their wear and tear provokes the tightening of the metal stamping kit

What is the importance of shape?

Manufacturing parts from steel does not imply savings on working equipment. It is important to select a stamping kit with a suitable edge shape. It is necessary to monitor the strength indicators, which must exceed the strength of the processed material, in this case steel.

The expediency of using this or that stamping kit largely determines the speed and productivity of work. For example, a straight and bent tool is suitable for machining external surfaces. When you need to cut off a part of a work piece or turn a groove, a metal stamping kit comes to the rescue.

Is metal stamping process long?

Furthermore, the process of processing a product by grinding is quite long. It takes about 70% of the total work piece time. This type of protective and decorative finish is half the cost of the finished part! In mass in-line production, the entire grinding process automates.

What is a turner in metal stamping?

A turner is a metal jeweler, since very often he has to work on complex parts of all possible thicknesses. Here you cannot do without milling machines and knowledge of all types of milling work.

Further, the surface can be anything: flat, threaded, or serrated. Milling today is extremely popular due to its high efficiency, so every novice turner should master its basic techniques.

What are the types of metalworking?

We list the main types of metal stamping kit of metalworking: 

• Horizontal and vertical type (according to the location of the working surface);
• Operations with passing and counter rotation of the stamping kit;
• End works (processing of undercuts, wells, grooves, windows);
• Shaped milling of profiles;
• Face processing of overall surfaces.

Furthermore, using all of the above types of work on milling machines, you can quickly and efficiently process casting molds and decorative elements, parts and instrument cases, door and cabinet numbers, letters for different plates. Also, the ability to produce clichés, badges, badges, and make advertising products will not be superfluous.

Milling recommendations for milling process

Now let me share some recommendations regarding the milling process itself:

1. For face milling, avoid machining planes with intersecting holes and slots.
2. The cutting process will be intermittent, which will disrupt the work of the cutting edges.
3. It is better to make the hole later or, in extreme cases, halve the feed amount;
4. If the work is going on with a large surface, the contact of the metal stamping kitwith the work piece must be continuous;
5. The radius of machining of the corner sections of the stamping kit must be larger than the radius of the stamping kit.

What is 3D milling?

As for the shaped type of milling work on metal, then on a conventional machine it is easy to do only in the case of a curved profile of the work piece in one section. When a part has a curved profile in two sections, then its processing is possible only on special equipment.

Moreover, if you are fortunate enough to be a numerically controlled machine operator, you have the opportunity to create complex three-dimensional products, that is, practice 3D milling. Typically, such devices are common in advertising, industry, instrument making.

What to buy a metal stamping kit?

When you decide to purchase metal stamping kit for personal use or professional activity, you should pay attention to the power and speed of the grinding machines. It is important that the manufacturer's stated wattage balances against the other specifications of the device.

The speed of the car should also be “in tune” with the torque. Smart electronics of the instrument and protection against overheating will become an excellent assistant in your work.

Therefore, in order for working on a lathe to provide you with income for your long and happy life, you must follow simple rules.

Bending die processing: principle of operation, advantages, application

Bending die of metal is carried out with a laser beam. Compared to conventional light, the laser is directional, monochromatic and coherent. Moreover, these properties provide the most accurate focus on a small metal surface.

Generally, the concentration of energy allows the material to get heat. Furthermore,  gas and solid-state lasers are commonly common.

The first ones are the most optimal in terms of price and quality of work.  The installation is a working table on which a beam with a laser head is attached. The work piece movement system operates on a linear drive. The installation of bending die is under the control of a computer. Furthermore, this works according to the cutting programs embedded in it.

How to work properly and professionally with bending die?

In order for the process to be of high quality, the required cutting width is observed, so that the work takes place strictly in the heat-affected zone, it is important to observe the technological parameters:

• Generally, repetition frequency, duration of pulses when operating in a pulsed mode;
• Radiation power and cutting speed;
• Similarly, diameter of the laser- spot;
• Furthermore, auxiliary gas pressure.

Each of the above factors affects different materials in different ways. Similarly, it is important to consider whether you are working with stainless steel, titanium, aluminum, copper or brass, mild steel. The correct bending die will ensure a smooth and smooth bend.

How to choose bending die quality?

One of the most frequently asked questions to me is how to determine the die quality. The main criterion is the degree of surface roughness. As you move deeper into the metal, the quality will decrease. In addition, it is important to monitor oxygen pressure and cutting speed here.

Benefits of bending die metal

At one time, the principle of operation of bending die cutting and the attractiveness of the workflow prompted me to take up this particular cutting method.

Undeniable advantages of bending die technology: 

• You can cut any materials with different thermo physical properties;
• With a minimum heat-affected zone, it is easy to get a cut up to 1 mm wide;
• Parts during processing practically do not deform, therefore, this method of metal processing can be safely applied to products with low rigidity;
• It is possible to make complex parts of original shapes;
• Flat and volumetric parts along a complex contour are processed automatically;
• You can change the shape of the part at any time, which eliminates the need for stamps;
• Low processing cost, which increases the demand for this bending die

Despite all its advantages, the technology is not at all universal. You should know that you can only achieve an ideal result with steel; the thickness is not more than 6 mm. For metal more than 40 mm thick, this method is generally contraindicated. Plasma or oxygen cutting is common there.

Reasons for the popularity of the bending die method

Based on my own, fortunately, successful, experience, I can say with sovereignty that having mastered bending die, you will never be left without work. This technology is moving forward to a leading position among various bending die processing methods.

Scope of bending die:

• Shaped cutting of sheet steel;
• Execution of complex shapes in design (decorative elements, stencils, etc.);
• Manufacturing of complex parts for commercial equipment;
• Release of products for the production of advertising products;
• Use in small-scale production of parts.

For laser technologies, not only the future, but also the present, so it never hurts to master promising, demanded knowledge and skills.

Why is bending die not complete today without milling work? 

This modern and very successful technology has significantly expanded the possibilities of straight and true shape nesting.  Having learned how to deftly operate the machine, you will be able to:

• Carry out piece and serial orders;
• Make an accurate and even cut;
• Give it the desired shape, depth and even make shaped cuts;
• Work on inclined, vertical and horizontal surfaces;
• To make carved decorative elements.

Choosing a milling and engraving machine for the bending die is directly related to your ambition as a professional. The more advanced a technique is, the more options it has.

How is milling and engraving useful in bending die?

Modern machines are models with CNC and the ability to manufacture products for various purposes. They allow you to carry out complex orders, to do artistic work. The universal machines behave very well, on which you can mill at various angles, in any position and with a variety of tools. To cope with any kind of work, you should use certain types of cutters.

The use of several methods of milling and engraving work on metal will help to get the desired result for bending die. If you move the cutter in the direction of rotation of the work piece, you get a very smooth and clean surface.

In this case, you need to fill your hand, since the work piece can fly out when a large layer of metal is removed. To improve productivity, cut towards the work piece. These techniques are often combined.

How to choose bending die tools?

Of course, everyone wants to achieve maximum results by reducing the cost of the work process. Nothing is impossible.

For example, if you work with end mills, remember that imported counterparts are more expensive. When choosing a tool for bending die, you should pay attention to the pitch of the plates. Each manufacturer places its own price on products, so you should choose carefully.

The quality of milling work is also affected by:

1. High rigidity of the bed;
2. Decrease in the power of the machine during finishing work;
3. The use of a large number of inserts (also for finishing);
4. Shallow cutting depth (helps to avoid chip problems).

Summary

The need of professional bending die company is crucial for long-term projects. That is why in this article we have tried to convey you the modern ways of doing ending projects for metal industry.

Progressive stamping tool is the finishing of a work piece. It is necessary to obtain a smooth surface of the part. With the help of grinding, minor defects of previous operations are eliminated.

This process is subdivided into several types:

• Rough
• Flat
• Round grinding
• Sharpening
• Polishing

I must say that this process is quite laborious. This requires special tools and abrasives.

Recommendations for completing the surface treatment of metal parts

In every metalworking job, it's important to pay attention to the many things like progressive stamping tool. There are no formulas and axioms for success. In order for the result of the work done to match your idea or the customer's project, I advise you to choose the right materials and type of processing. It will not hurt to practice to fill your hand.

What are the important things to consider while sanding metal parts?

Here are some things to consider when sanding metal parts:

Abrasive type. Coarse-grained materials are common for hard metals, and for soft alloys, analogs with fine grain are suitable.

Grinding type. For example, roughing is necessary to remove rust, dirt and other foreign matter from the metal.

The need for manual processing. This technique gives the metal an aesthetic look with the help of progressive stamping tool. For its implementation, waterproof skins with micro abrasives are common. To make it convenient to manipulate the skin, it is attached to a wooden block.

 

Specificity of polishing: Usually this super finishing carries out using special wheels and skins. In order for the surface to become completely perfect, you should not neglect powders and pastes.

Why metal grinder is selected more consciously?

The use of a good modern metal grinder ensures a high quality finish. An important selection criterion is the number of possibilities for a particular type of equipment. It is great when the unit allows you to process parts of various shapes, configurations, and sizes.

Moreover, only manual processing progressive stamping tool is indispensable for a professional. For example, products made of hardened steel are ground exclusively on machines.

How to evaluate the result of the progressive stamping tool?

The surface of the work piece or product must be completely smooth: without traces of feed and other defects that can often comes by vibration of the table or vibration of the grinding wheel. After high-quality machine grinding, polishing is no longer necessary. Also, do not remove the finishing shavings.

Useful and simple guidelines for bending reinforcement

Manual bending of rebar is only possible in third-rate Hollywood action films. In reality, this laborious process will require a special machine and a certain qualification. To cope with this task, it is necessary to have knowledge of the characteristics and properties of the starting material.

Moreover, as well as the operator must be able to correctly set up the equipment for progressive stamping tool, know how it works and apply the appropriate bending techniques.

Why modern device are common?

Modern devices make it possible to simplify and mechanize work with metal as much as possible. Rebar bending machines are of various modifications:

• manual;
• metal;
• hydraulic;

They are common for making staples and hinges, billets with a double bend, embedded parts.

Equipment for metal bending: getting started

Learning to operate the machine is not difficult. I will say from my own experience that it is important to follow two rules: follow the instructions and not neglect safety precautions. I present to everyone interested in the success of their work the following recommendations:

• Make sure you are using the correct set of rollers for the selected rebar thickness
• Delve into the characteristics of the progressive stamping tool
• Work only with protective gloves
• Start by bending one metal bar.
• Stand in a comfortable position so that you can quickly move away from the equipment
• When removing the reinforcement, it is important not to hook the pedal.

How to do when a drawing is there?

If you have a drawing in front of you and clearly understand the purpose of all the components of the device, as well as the principle of their operation, then “do it yourself” model can be easily assembled from scrap materials. To do this, you need ordinary channels, steel corners, bolts and nuts.

In order for a homemade manual rebar progressive stamping tool to fulfill its purpose, its strength must exceed the strength of the rods and rods. All fasteners must be absolutely secure. Moving parts must not have any play.

Why is organization of work place important?

The correct organization of the workplace is also important when working with any type of machine. The supply of blanks and storage of finished parts are carried out from opposite sides. It is impossible that there are foreign objects nearby.

Stamping tool is the process of removing a thin layer of shavings using abrasive wheels and skins. The operation has high accuracy; it is the final stage of the part processing. Grinding and polishing processes

How does grinding work?

The abrasive wheel rotates and moves in a specific way relative to the work piece. The result of such progressive stamping tool is a smooth surface without the slightest defects.

Each abrasive wheel has its own grain size. Do not use coarse abrasives when sanding soft metal products. The choice of wheel or pelt is dictated by the type of sanding.

What are the types of grinding?

I will say a few words about the features of each type of grinding.

Rough grinding is common to remove a metal layer containing dirt and rust. Here you need a circle with large grains. The complexity of the process involves the use of power tools.

Surface grinding carries out around the periphery with the end of the wheel.

The round grinding comes with a transverse, longitudinal, axial feed, it can be center.

Special works are common on carved surfaces, when machining shaped parts.

Internal grinding of the holes of the rotating part takes place with a longitudinal or transverse feed; the process can also be center less. When the part is static, planetary feed is important.