The Basics Of Metal Broaching...

While not as commonly used as different types of metal machining, metal broaching is a very reliable and precise way to create specific shapes on the surface of metal parts and components. Like machining, broaching removes small chips from the surface of the metal to create the desired shape, and like machining the process can be used on the exterior as well as the interior surface. In general, broaching is a process that is best and most effectively done with harder types of metals and alloys. Most companies that offer metal broaching use this method on materials that fall into the range of 10 to 32 Rockwell C hardness, with softer materials not suitable as they do not form chips easily and this limits the effectiveness of the chip removal in the process. Likewise, materials that are too hard do not lend themselves to the necessary removal of the surface of the part. The Process In metal broaching, either the workpiece can move, or the broach tool can move. The cutting tool, the broach, is made with a customized set of teeth, which are in specific rows and configurations. This configuration starts with a smaller dimension in the first row of teeth and gets progressively larger until the desired dimension along the tool. As the workpiece or the tool is moved, the smaller teeth and progressively larger teeth remove a small layer of the surface, pulling the chip down to the end of the workpiece or to the desired shape. Depending on the complexity of the design, the process may be completed in a single pass, or the shape can be created with a single pass. This is an extremely precise method of cutting shapes into the surface of metal. It is used for...

The Advantages Of Robotic Welding Services...

There are many different types of welding processes, and each has its advantages when used with various metals and alloys. Today, thanks to the benefits of technology, most of these welding options are available through conventional welding as well as robotic welding. Conventional welding, which is done by a trained welder, has long been the gold standard for creating durable joints for both prototyping as well as for production. However, with any type of manual welding operation, there are slight variations in the weld. Setting up robotic processes to complete the welding on small to large volume orders can remove these variations and provide precision welding services between parts and components in the same order and across orders over time. Faster Processing The use of robotic welding also speeds up the process. The robotic system never gets tired or takes a break, and it can operate around the clock with faster production than possible with conventional welding. At the same time, this faster production does not have any loss of weld quality or consistency. This translates into less waste and no need to continually quality check welds after the process is completed. Multiple Programmed Welds The use of robotic welding also allows the fabrication shop to program the system once for the part or component, even if there are multiple joints involved in the fabrication. Once this program has been saved to the system and the equipment set up, all that is required is operator oversight. One operator can monitor multiple robotic arms, and changing from one job to another is as easy as simply changing the control program. As the robotic arm is controlled exactly the same for every weld, precision is a natural outcome of this fabrication choice. A significant benefit to...

Tips for Tube Bending – and Why It’s Okay to Call in a Pro...

If you’ve ever tried bending a tube or pipe to fit your needs, you may have noticed how difficult the task can be. Here are some tips from industry experts on how to get a great-fitting, custom-bent pipe: Ensure a Proper Fit When using pipe bending tools to create custom-bent tubing, it is important that your tools are set to the right specifications for your pipe. Both the bender roller and former should be adjusted accordingly to ensure a snug fit during the bending process. Failing to make this adjustment before using a hydraulic pipe bender or any other tool may result in slippage, improper bending, damage to the pipes or bending device or even injury to the operator. Practice Makes Perfect Tube bending seems like it should be a simple task, and for those who are experienced in the industry, it does come easily. That isn’t because the task is inherently simple, but instead because of many hours of practice. If you’re looking to make tube bending part of your business offerings, it’s important to log hours of practice for every staff member who will be working with tubes. Some key points to remember: The tubes you will work with are typically joined or fixed at one end, so getting an accurate measurement entails measuring from the middle point and moving outward. Piping often rebounds slightly after bending, so over bending – just the right amount – is part of the proper technique. Smooth motions make for better pipes, so practice making fluid, simple motions to create the customized designs you need. Reinforce Weaker Pipes Pipes that are made of weaker metals such as aluminum tend to ripple or crimp during the bending process. To prevent this, reinforcement of the tube before bending...

Custom Sheet Metal Fabrication: Using Aluminum...

Sometimes, a standard form or component cannot deliver the required result. When a traditional or customary part is not suitable, a manufacturer may opt for customization. For metalworking shops interested in satisfying the needs of all their customers, custom sheet metal fabrication is an integral aspect of their production services. While steel and stainless steel are common metals for this process, aluminum is also prevalent. Why Choose Aluminum Sheet Metal? Aluminum has always been a popular choice among diverse industries. For residential, commercial and industrial use, the product garners praise for its qualities. Whether in standard or custom work, aluminum offers certain appealing characteristics. It is: Lightweight Tough Malleable This makes it ideal for certain applications. Applications Whenever a unique solution is necessary, rather than provide a standard option, companies request a customized version. Whether the demand is for a complex new part or the creation of a prototype, experienced fabricators offer this service. When it comes to aluminum, custom sheet metal fabrication shops understand the need to complete the project to exacting specifications, meeting all the requirements of the manufacturer. They may also offer value-added services to ensure industries view them as a one-stop service provider. Industrial concerns requesting such services are: Aerospace – Aluminum comprises many components of military, regular and space aircraft Automotive – Various vehicle parts use plate and sheet aluminum Marine – Boat floors and other components utilize aluminum Railway trains – Aluminum is practical for such items as fuselages While standard products are available in the above areas, customization is increasingly essential for many industries. Fabrication companies can easily deliver customized designs that meet or even exceed the requirements. Custom Sheet Metal Fabrication Modern fabrication shops offer a variety of services. Some of them are value-added options. Diversification...