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Cost Saving Welding Tips For Your Next Welding Project!

welding

The sheet metal fabrication process is an essential undertaking. It adds value to any construction work. The strength of the weld determines the effectiveness of the welding process. Like any other project, welding requires money and time.

Labor costs and input costs can increase the cost of welding if not well managed. A cheap one always does not mean quality. Look for cost-effective solutions to ensure the profitability of your next welding project?

As an entrepreneur, you need to consider the resource combination that saves money. Thus, you need to choose the right welding partner to achieve your goals. Do you intend to cut costs on your next welding project? Here are a few tips to get you started.

1.Plan Before The Welding Project Begins

Planning is an essential process in the budget-making process. Cut down the expenses by making preparations for your welding. Perform a study to find out the materials you need and estimate the costs involved.

Many people ignore the planning stage. It makes a difference by eliminating mistakes and undervaluation during the fabrication process.

Early preparation will help you stay focused. It will also assist in estimating the costs and completion time. Ensure that you work with a trusted welding professional. It can help you find out the costs of materials required.

Discuss with your welding expert the construction design you intend to make. If the design resembles your previous projects, provide documented drawings for review.

Before the project begins, work with your trusted welder. This way, you can change product designs and drop unnecessary welds.

2. Save Time By Arranging Welding Materials.

Procuring the materials needed for the welding before the operation begins saves time. Put the necessary materials close to a professional welder to avoid lag time. When a welder looks for welding accessories that are far away, the waste of time will increase.

You can sort the welding materials needed and arrange them close to the working area. Before the welding operation begins, the welder should prepare the materials. It will improve productivity.

Welding accessories scattered may cause interruptions. So, you should sort and arrange them.

You need to prepare joints before the commencement of the welding activity. The welding professional should ensure that base surfaces maintain a level of cleanliness.

Cleaning eliminates contamination from pollutants such as air and oil. He should detect and reduce gaps to prevent over welding and wastage of fillers.

When you have everything set, the welding operation can begin without interruptions.

3. Look For An Experienced Welding Contractor.

Experience is necessary for the metal fabrication process. To avoid time and material wastage, you should choose professional welders. They should have years of proven experience in the fabrication industry. Look for certified and well-established welders with skills in metal fabrication.

Expert fabricators can estimate the value of resources needed to complete your project.

Welders can determine the proper procedures to avoid distortions and warping. These may impact the final end product. Professional welders also do not make try and error methods in their operations.

Working with an experienced fabricator contractor will get high-quality products. Always use welders who have worked on projects like yours.

You can find professional welding contractors through testimonials or referrals. Online platforms also help professionals find reliable and efficient suppliers for welding operations.

4.Incorporate Automation In The Welding Process.

You can increase the efficiency of the fabrication process. For this, incorporate some welding functions. It can be automatic mechanization as well.

Automation helps in speeding up the process without compromising productivity. The use of machines can streamline the weldment through complex procedures. In such a procedure, turning rolls, weld positioners, and manipulators operate.

The automation equipment will help reduce costs by eliminating functions. But it would need a lot of human labor.

Human beings are prone to errors and fatigue. Machines can replace human beings in scenarios where automation is possible. Robotic welding is also a new trend in the fabrication industry. It cuts down on labor.

You should buy new technologies that enhance efficiency and productivity. For example, gas tungsten technologies help to speed up the welding process.

Automation of various welding procedures streamlines services helping to cut down costs.

welding

5.Proper Maintenance of Welding Equipment.

Machine breakdown during the welding process means a waste of both time and money. To avoid such unprecedented events from occurring, schedule machine maintenance. You must maintain the welding equipment to function.

Faulty equipment increases production costs while reducing the efficiency of the welding process. For example, maintained appliances will lead to voltage losses.

Moreover, a flawed gas system will result in gas leakages that will be a health hazard to welders.

Faulty tools will also decrease the efficiency of the welding operations. It can lead to poor-quality welds. Poorly-done welds will increase costs and the number of rejected products.

Regular maintenance of the welding tools will keep them in a suitable condition. All faulty equipment needs replaced with new ones.

6.Regulate The Use Of Consumables.

You can cut down the welding cost. For this, you should control the usage of consumables. For example; grinding wheels, filler metals, and shielding gas.

You should ensure that you use the consumables when necessary. This way, you can decrease the cost and avoid wastage.

Regular checks on the gas delivery system will help to identify gas leaks. This regular checkup prevents losses. In the long run, it will drive the total cost of production down.

7) Refrain From Over-welding.

You should ensure that the welding operations follow the original plan. Overwhelming occurs when the fabricator applies a large weld than needed.

Over-welds may also happen when you fail to specify the size of the design to your fabricators. When this happens, it increases the cost of materials in the long run.

The use of extra material means that more heat usage. Heat can lead to the distortion of the product hence reducing efficiencies.

Inexperienced fabricators make overwhelming mistakes. They want to ensure the usage of enough metal in a welding operation.

Overwhelming leads to poor quality products and wastage of resources. A quarter-inch increase in the fillet weld will result in extra costs.

You can cut the overwhelming mistakes by hiring experts in the fabrication industry. An experienced welder knows to stick to the client’s budget and measurements.

welding

8.Follow The Proper Welding Procedures.

You can produce high-quality products if you follow the proper procedure for operations.

The appropriate production methods involve using the correct amount of heat. Also, ensure that the surfaces don’t get overwhelmed.

In the fabrication process, the sequence of conducting operations matters a lot. Welding is an art and science that only experienced fabricators can understand. Fabrication involves high temperatures. It can lead to warping and distortions if not controlled.

Proper welding techniques and procedures end undesired distortions and warping.

Professional fabricators have the skills to judge the expected changes. They can make adjustments for a better quality finish.

Employing experienced fabricators will guarantee reduced fabrication time. The production of high-quality welds will be high.

welding

9.Incorporate Fabrication Costs With Other Welding Expenses.

Many welding professionals can perform other manufacturing procedures such as machining and painting. You can reduce costs by bundling fabrication costs with other welding expenses. For this, you need to work on a tight budget.

Get a fabrication expert with experience in machining and painting. It can help you get a discount on the total price of operations.

To get a discount, you can hire a welding expert who will help you buy various welding materials.

Categorize welding expenses and divide them into a fabrication expert. It will lower the costs than carrying out these functions as independent projects.

10.Ensure Adherence To Safety Standards.

Welding operations should follow suitable safety precautions to avoid accidents in the workplace.

The welding professionals should wear safety gear. They must handle welding equipment as stipulated in the health and safety standards

Improper tool handling can lead to wastage of resources which will be costly in the long run. Accidents can derail your fabrication operations. It can increase the time needed to complete the project.

Get insured workers to avoid the extra cost if unforeseen accidents happen. The welding equipment used must conform to international standards.

welding

Final Thoughts

QBH Technology is an industry leader in the manufacturing and fabrication processes. We have state-of-the-art facilities for the production of high-quality metal. For your industrial purposes, you can trust us.

We care about our clients. We provide cutting-edge technologies in CNC machining and welding. We undertake your project as our own to ensure we deliver the project as required. We have a team of certified engineers who will help you throughout the planning process.

Our welding department utilizes advanced technology.

We provide high-quality services at affordable prices. We also do follow-ups to ensure you receive the best service for all your needs.

Our experts have a wealth of experience in CNC technologies and milling. You can trust us with your project, and we will be happy to take it to completion. Contact us today for a quote.

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8 Questions to Ask Your Custom Metal Parts Manufacturer

Metal Parts

Are you thinking to order custom metal parts from your manufacturer? Usually, it is a difficult and frustrating decision to trust a manufacturer while giving metal parts orders to him. Although, it is. If your manufacturer is qualified, experienced, and contract manufacturer. Then he will have wealth of knowledge to ensure your product is best.

However, you should have some things to discuss with your manufacturer before working with him. Additionally, as bad as, the situation is if you don’t know how to discuss things with your manufacturer about metal products. To overcome these difficulties, we have 8 questions to ask the manufacturer before you are ordering metal parts from him.

These questions will help you, what you should discuss with the manufacturer if you are contracting to him for custom metal parts.

You should compulsorily ask these questions to your custom metal parts manufacturer. These important questions are.

metal parts

1. How do you ensure your need regulations? and tell me about your certifications.

When you are considering a manufacturer, you should be sure about his proper certifications to complete the project accurately. Although he is an experienced, well-qualified and contractor supplier, he should prove his qualities in front of you. This will be your level of satisfaction for your project completion with high accuracy. The manufacturer should be able in front of you to analyze your metal parts project.

It is good to discuss all the things before doing a contract between you and your manufacturer. Manufacturers should understand on regulatory requirements of the project. You should know about the safety and material compliances and all other precautions when the products come in touch with other working metal parts. Understanding all these precautions, analyzing the project and complete working of final product production are compulsory things to understand the safety measures while all this process. Your manufacturer should know about all aspects, pros, and cons before working on your project.

2. Which material is best to produce my custom metal parts project?

This is a very important question to ask because raw materials and technical spaces vary from country to country. And the manufacturer thinks about them differently. They believe in different supply chains for their projects. Before this discussion with your manufacturer, you should give you international metal equivalent to the metal parts production. You should also visit the plan of international metal expert productions. Plan how to choose the best quality material for your metal products manufacturing.

Also clear this think to your manufacturer about the quality of metal products. Never trust a low-quality material to use in your metal parts production. Many metals seem the same or closely match each other. But they are different in their chemical properties. Be careful about the quality of metal that is using in your metal parts production. Because the reputation of your company surely depends on the quality of your products. While Cheap raw- material would not be a good choice for your metal products. You should make a plan of long-term viability, balance, quality, and cost-effectiveness about the final product of the metal part project.

metal parts

3. Have you done this before and how will you manage this project?

If your manufacturer is certified in his work accuracy. Then he should be able to relate his experience with his present project and he should improve his process of working on the project if there is a need. Ask about the best manufacturing process for your project. You should know about the scope of your project. Because scope plays a vital role in determining and manufacturing process in the best way.

Discover the risks associated with the manufacturing of the project. You should also know that where the process will be executed. You should also ask the manufacturer about the way to save time and money while maintaining the quality of the final product.

4. When you will fulfill my order or what happens if the order fails to arrive on time?

It is also a very important question to ask from a manufacturer because due to a tight time schedule, usually manufacturers can not make the parts themselves and they go to a third party for the production. This is a major problem through which manufacturers cannot fulfill their commitments of products’ timely delivery. Ask them about the time schedule. Give easy time to your manufacturer to have the best quality material for your metal parts production. Ask your manufacturer about the time schedule which is compulsory to have for the perfect way of working.

You should also have some independent research about the manufacturer’s previous record. Also, meet the previous clients of that manufacturer and take reviews about the manufacturer’s performance. Fix a time for the delivery of final parts.

Enquire if the order arrived late the manufacturer will compensate for the inconvenience.

5. What will be the total cost of the order and the price will change at what condition?

In some cases, the manufacturer may not include the total cost of the products. As a result, he will say to pay more from the budget that he has to explain in front of you. Additionally, the manufacturer may include costs of delivery fees and fuel charges. Also, discuss the circumstances through which the price could be changed. To avoid all these inconveniences, ask the manufacturer to estimate the total budget for your project. Ask the manufacturer about the budget if the product is directly sold to the market customer.

Compare the budget of a manufacturer to the amount which is affordable to you. If the budget of the manufacturer is more than your estimate. Do not go with that manufacturer with the material of low price. Do not compromise on the quality of raw material at any condition.

metal parts

6. Will the manufacturer give surety of accuracy and insurance certificate with the delivery of your project?

A good manufacturer will surely provide you all certificates, necessary for the project. Manufacturers will take responsibility for product quality.

If the manufacturer has good knowledge and experience about your project manufacturing. He will be happy to give you the surety of the project. The manufacturer will feel happy to give you the insurance certificate. In this way, he can get a good reputation for performance.

Discuss with your manufacturer the testing process of metal production. For better performance metal parts must be tested randomly before it’s application.

  • Ask the manufacturer about the limitation of his equipment.
  • Discuss the effect of quality inspection.

7. How seriously do you take safety while customer metal parts production?

Ask about the whole pieces of equipment and tools which play a vital role in the complete process. Visit his equipment set up and also monitor his measurements of safety. Also, take review about the previous performance of customer services.

Additionally, if you are paying a huge amount for your project. Ask about safety measures. Discuss with the manufacturer, for offer discounts to his clients.

Typically, he must offer you some discount on your project. Enjoy the discount. Ensure that you have the decided budget to pay at the exact time. Also, ensure that you can rely on the manufacturer with the right material and perfect quality. Usually, stainless steel is the best material to use in metal parts production projects. Decide on a day to pay some amount earlier and the rest of the amount before the delivery of your project.

8. Can I schedule a sudden visit while my project completion process?

Before giving the order metal parts to the manufacturer. You should have independent and basic research about the project.

Keep an eye on the material, which is using in your project. You should have a sudden visit to the company or manufacturer to check all about your project.

Ensure quality, on-time delivery, and safety measures. Ask your manufacturer for your sudden visit. You should clear all the needs of your manufacturer that he expects from you in your project.

Some Important discussions with the manufacturer

  • Before putting your order keep in mind all these questions to ask your manufacturer. Built written contract to the manufacturer to avoid any inconvenience.
  • Clear all your conditions to your manufacturer before the contract. Don’t pay the whole amount to your manufacturer before the delivery of your project.
  • Ask the manufacturer if he offers special finishes.
  • Be sure about the quality, material, and timely delivery. Satisfy yourself by checking certificates and the reputation of the manufacturer.
  • You should ask the manufacturer about the experience of the same application. Discuss the amount negotiable. Be sure the complete order budget is affordable to you.
  • It plays a vital role to find the best manufacturer for your custom metal parts production. That depends on your company’s own obligations
  • Therefore, you must be very careful while finding the best manufacturer for your custom metal parts production. It will be a favor to your money and company’s reputation.

If you have any questions or confusion. You are free to please ask in the  comment box. And leave a reply. We will get back to you as soon as  possible.

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6061 vs. 7075 Aluminum: Which One is Better for Your Project?

7075

Introduction

Aluminum continues to be one of the most used materials across industries. And the reasons are quite simple. Aluminum showcases an impressive strength-to-weight ratio and has excellent relative machinability. However, you might have to do some due diligence to choose a suitable aluminum alloy. Since most projects will require 6061 or 7075 aluminum alloy, we will discuss them inside and out in this post. So, which aluminum alloy is best for your upcoming project? Let’s find out, shall we?

What is 6061 aluminum alloy?

A renowned member of the 6000 series, 6061 aluminum alloy is often regarded as the jack of all trades. Why? The 6061 aluminum alloy showcases excellent mechanical properties, corrosion resistance, and versatility.

Not just that, the sheer low cost of preparation also makes it highly lucrative for different projects.

6061 is the most versatile heat-treatable aluminum alloy that was developed in 1935. It was initially called ‘Alloy 61S’. 6061 aluminum alloy is easy to fabricate and exhibits excellent formability.

Speaking of its formation, the 6061 aluminum alloy is made of 95.8 to 98.6 percent aluminum, 0.8 to 1.2 percent magnesium, and 0.4 to 0.8 percent silicon. Such alloys usually show traces of copper, chromium, and other elements.

We will discuss the mechanical and chemical properties of 6061 aluminum alloy in a moment. But before we do that, let’s discuss the areas and fields where you can use this popular aluminum alloy.

CNC machining

What are 6061 aluminum alloy applications?

Since 6061 is highly versatile in its properties as well as applications, you can use it to fulfill any structural requirement. You will always find vehicles, both personal and commercial, using the 6061 aluminum alloy. The alloy is mainly used to build frames and running boards.

Not just that, you will find ample areas of application of 6061 aluminum alloy in infrastructure as well. The allow finds application in structuring mass transit and subway platforms. You will often find 6061 aluminum alloy on steps, walkways, cover plates, and even on floors.

We have also found its applications across consumer goods! Most modern bicycle brands use 6061 aluminum alloy to develop the frame and related components. It is even used in SCUBA tanks, small boats, and fishing reels! After all, the alloy has immense strength to undergo high stress and hot forging.

What is 7075 aluminum alloy?

Right after the development of the 6061 aluminum in 1935, a Japanese company came out with the 7075 aluminum alloy in 1936. The alloy was later made available for industrial application in 1943 by Alcoa, an aluminum supplier.

7075 aluminum alloy, a member of the 7000 series, is known for its high strength and impressive strength-to-weight ratio. It showcases commanding mechanical properties, which we will discuss in a moment. Most importantly, this aluminum alloy has superb resistance to fatigue and good ductility. No wonder why it is used to build structural parts of an aircraft.

The 7075 aluminum alloy contains zinc (5.6 to 6.1 percent), magnesium (2.1 to 2.5 percent), and copper (1.2 to 1.6 percent). Besides them, the alloy also contains silicon, titanium, chromium, manganese, iron, and other elements. Let’s discuss its applications!

Where is 7075 aluminum alloy used?

This is a no-brainer. Given the high strength-to-weight ratio and overall improved strength, the 7075 aluminum alloy is well equipped to handle the high stress across aerospace, marine, and transportation industries.

These industries require building materials that are lightweight and showcase high-strength properties. And 7075 aluminum alloy qualifies quite easily. You will find this alloy being used by high-end bicycle brands. Airframes and rifles utilize the 7075 aluminum alloy as well.

7075 is often regarded as ‘aircraft grade’ because it is one of the highest strength aluminum alloys used in the industry. Its applications never cease across aircraft, missiles, spacecraft, and other defense-related products.

sheet metal fabrication

Mechanical differences between 6061 and 7075 aluminum

Let’s continue our discussion about the mechanical properties of the aluminum alloys in question. Here are the mechanical properties you will want to consider when choosing between 6061 and 7075 aluminum alloys:

1. Thermal conductivity

Aluminum alloys never disappoint when it comes to heat conductivity. They are generally great conductors of heat. However, 7075 and 6061 aluminum alloys have quite a difference in their thermal conductivity. 6061 aluminum alloy has a higher thermal conductivity than 7075 aluminum. So, you will want to use 6061 aluminum if heat dissipation is the primary purpose.

2. Elasticity

Elasticity is the measure of a material’s stiffness. In other words, you will want to check the material’s resilience before putting it to use. Elasticity will also help you identify the material’s resistance to deformation. The good thing is that both 6061 and 7075 aluminum alloys have similar elasticity.

3. Electrical resistivity

A low electrical resistivity means the material has good electrical conductivity and vice versa. Speaking of the aluminum alloys in question, you will find that both 7075 and 6061 aluminum have excellent electrical conductivity. But, 6061 aluminum has lower electrical resistivity than 7075. So, you will want to use it if you need a material with high electrical conductivity.

4. Corrosion resistance

7075 aluminum is more prone to corrosion because it contains a higher percentage of copper. Copper usually reacts quickly with the environment and causes corrosion.

5. Yield strength

Yield strength is essentially a material’s ability to withstand pressure and impact without deformation. 7075 aluminum alloy has higher yield strength than 6061 aluminum. The former’s yield strength is higher due to the higher percentage of zinc. However, 6061 doesn’t have a bad yield strength. It has a yield strength of 276MPa.

6. Temperature resistance

Temperature resistance is the measure of a material’s ability to withstand heat without causing deformation. In other words, you will want to know the melting points of both the alloys before you decide which one to use for your project. 7075 aluminum (477 – 635 degrees Celcius) has a lower melting point than 6061 aluminum (582 – 652 degrees Celcius). Thus, 6061 aluminum alloy is perfect for projects that undergo high heat treatment.

7. Material hardness

The harder a material, the higher its chances to fight indentation, penetration, and other deforming forces will be. Material hardness is a significant factor when it comes to choosing between 6061 and 7075 aluminum alloys. To be precise, 7075 aluminum alloy is harder than 6061 aluminum.

Chemical differences between 6061 and 7075 aluminum

One would also be interested in the chemical differences between the two important aluminum alloys. Indeed, the chemical differences between 6061 and 7075 aluminum alloys aren’t readily visible. But, you will still want to consider them.

Why? The availability of elements like magnesium, silicon, copper, iron, zinc, titanium, manganese, and chromium have a significant impact on the alloy’s weldability and workability. To be specific, you will want to know the percentage of zinc in each alloy.

Since 6061 contains less zinc than 7075, you will find it easier to weld 6061 aluminum alloy than 7075. It will also have superior workability. At the same time, 6061 will not showcase the high strength and stress resistance of 7075.

sheet metal

Summary: Which alloy to choose between 6061 and 7075?

Both 6061 and 7075 aluminum alloys have impressive mechanical properties. But, you will want to use 7075 if your project requires high strength and low weight material. We suggest you use the 7075 aluminum alloy if the part will undergo a lot of heat and friction since material strength will be the key to project success. Since 7075 is expensive, use the alloy if the cost is less of a concern.

So, when should you use the 6061 aluminum alloy? We highly recommend 6061 aluminum alloy if the part requires a lot of machining and welding. Since 6061 is relatively cheaper, you should go for it if you are running a limited budget. Regardless, to make a good decision, we suggest you list your priorities and specific project requirements. It will help you make comprehensive distinctions between the alloys you are about to use.

Keep reading!

There you have it. We have shared everything you need to know about the two most important aluminum alloys – 6061 and 7075. The differences in material, properties, and applications have been well described in the post, which will help you make a highly informed decision for your project. Have questions? Comment down below. If you loved reading this post, don’t forget to check out other informative posts on the blog!

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  Types of Rivets_ A Guide to Rivet Types and Their Common Uses 

Aerospace Fasteners

What are Rivets Exactly?

Technically, a rivet can be called a permanent mechanical fastener or connector with a head at one end and a tail at the other end. The head of a rivet is smooth and the tail is cylindrical which resembles a metallic pin.

We are sure you must be aware of screws, bolts and nuts. These are commonly used in our homes to fasten or secure a home decor item. They are even used as connectors to join two pieces of wood or any other material. So, to put it simply, a rivet is a better version or a better replacement for screws, bolts, and nuts.   

Rivets are permanent fasteners which means that once installed they cannot be removed or reused. Even if they are removed after being installed, they won’t be of any further use.

Rivet

Installing Rivets

The installation process of rivets is fairly simple. A hole is punched or drilled onto the material that requires fastening. The rivet is then inserted and an impact is made on the smaller end to flatten the rivet and secure both the material and the rivet tightly together.

Riveted joints are very similar to bolted joints. There are basically two major types of joints used while installing rivets.

1) Lap Joints: In lap joints the two materials or components which are to be joined overlap each other. These joints are primarily used to join wood, plastic, or metal.

2) Butt Joints: In butt joints, there is no overlap but an extra material is used to join the two components. But joints are further classified into single strap butt and double strap butt based on the number of single plates used for joining the components.

The Riveting Process

While rivets are mechanical fasteners inserted through holes to join two parts together, the riveting process is a forging process through which the rivets join the two parts together. Both ends of the rivet consist of a permanently formed head which prevents the rivet from coming out and thus can securely join both parts.

During the installation process, the rivets undergo drilling or are punched into a hole. This causes the tail of the rivet to deform and also holds it in the desired place. The deformation of the tail makes the material flatter causing the tail to expand to a size about 1.5 times the original diameter of the stem. All of these mechanisms of rivets help to securely hold the material.

Material Used in Rivets

The rivets are mainly made up of steel, brass, aluminum, plastic, copper, etc. The choice of material depends on the desired usage. Any material that is used to make rivets must be tough and flexible. Ideally, the mechanical properties of the rivet should be similar to the components it is supposed to be fastening. Thus for example a plastic rivet is used to fasten soft materials.

Rivets made with different materials, have different properties and serve different purposes.

Steel Rivet: A steel rivet is tough and hence used in the aircraft, construction, and furniture industry.

Aluminum Rivet: An aluminum rivet is light in weight, corrosion-free, and durable. It is used in the aircraft, automotive, and air conditioning industries.

Brass Rivet: A brass rivet is tough and causes low friction making it an ideal rivet to be used in gas appliances.

Copper Rivet: A copper rivet is flexible, looks appealing, and is a good conductor of heat and electricity. These attributes of a copper rivet make it suitable to be used in electrical appliances.

High Carbon Steel Rivet: A rivet made with high carbon steel is hard, durable, and has a higher shelf life. It is used in the aircraft, automotive, and rail transport industries.

Plastic Rivet: Plastic rivets are soft and can be used to join soft and non-plastic materials such as rubbers.  Plastic rivets are mainly used in consumer appliances and the construction and furniture industry.

Copper-Nickel Rivet: A rivet made with a combination of copper and nickel is highly resistant to corrosion and high temperature. This rivet is used in manufacturing ships and in making appliances, especially for places with corrosive environments.

Stainless Steel Rivet: A stainless steel rivet is strong, hard, and also corrosion-resistant. All these properties make it useful in the aircraft, automotive, and rail transport industries.

On top of the materials used to make rivets, these rivets often have an additional coating of a material such as zinc to increase the shelf-life, strength, and resistance of the rivets from wear and tear.

Application of Rivets

Rivets are ideal fasteners when it comes to supporting shear and tensile loads and they have a supreme fastening ability due to which they are ideal for heavy-duty applications and hence are being used in major industries, prominent being aircraft and textile industry.

Construction of Aircrafts

Heavy-duty materials are used in aircraft. These heavy-duty materials need to be well-fastened together or they may come apart and cause an accident. Rivets help to establish a strong bond between the various parts used in the construction of aircraft. Using rivets also helps in quick inspection and maintenance of the aircraft which saves both time and cost of repairs.

Construction of Buildings

Lots and lots of metal sheets are used in the construction of buildings. Rivets are used to hold these metal sheets strongly. Rivets are even used in the installation of doors, windows, and roofs in construction owing to their strength and durability.

Furniture Work

Rivets are the primary materials used in the furniture industry to manufacture sturdier and superior furniture items. Using rivets causes less wear and tear in the furniture items such as drawers, shelves, handles, etc.

Jewelry and Clothing

Both the jewelry and clothing industries have benefited immensely from the use of rivets. A major problem that both these industries faced was coming apart of two pieces of jewelry or cloth material for that matter. Rivets can clamp the two pieces of cloth together permanently and have brought a shift in which cloths and jewellery were made.

Electronics and Appliances

Rivets are resistant to heat, chemicals, and corrosion. These properties of rivets are used in electronic appliances to fasten plastic and rubber components used in them. Due to this even, the shelf life of the appliances is increased.

Advantages of Riveting

The benefits of riveting in the manufacturing world are enormous. Some of the major advantages of riveting are as follows:

Cost-Effective

Production of rivets is very cheap as compared to alternatives such as adhesives and welding. There is no electricity cost and riveting also brings down the number of other materials required for fastening to a great extent. The cost of transportation in the case of rivets is also comparatively small owing to their small size.

Durable

Rivets can withstand excessive vibrations and impacts. They are resistant to corrosion, moisture, fatigue, and even chemicals. The materials used in rivets make them tolerant to high pressures and load. Rivets are also tolerant to heating and cooling thereby minimizing the effect of temperature and heat on the joints. All these properties make the rivets durable and increase the life of the part being joined together.

Strong and Flexible

Rivets come in different shapes and structures. Irrespective of the size and structures one thing that is common in rivets is that they are strong and flexible. They can be used in different combinations to suit the requirement and can be used to make joints at any place and any location.

Wide range of applications

Rivets can not only join ferrous materials but also non-ferrous materials such as aluminum and copper. They can even join non-metallic materials such as wood and plastic. Moreover, rivets can even join to objects made with different materials.

Environment Friendly

With riveting, there is no question of fumes arising which happens during welding. So it is better for both the environment and the operator.

Easy Maintenance

When compared to alternatives such as wielding, the time, cost, and effort required to maintain a riveted joint is minimal. A worn-off wielding means one has to go with the installation process all over again. On the other hand, a damaged rivet can be very easily and quickly reinstalled using basic equipment such as a riveting machine or hammer.

Types of Rivets

Rivets come in various kinds of shapes and sizes to meet the various kinds of requirements. The different types of rivets are as follows:

1) Solid Rivets

Solid rivets are one of the simplest and reliable types of rivets. They are also the most commonly used ones. Sold rivets are made up of a solid shaft with a head at one end. After installation, the headless end is deformed to keep it secured in the applied place.  

Solid rivets are available in round and 100° countersunk heads. Solid Rivets are most commonly used to make the frame of aircraft.

Solid Rivets

2) Blind Rivets

As the name suggests, Blind rivets can be installed completely from just one side. This property of blind rivets gives it several advantages such as that it can be installed by one operator without any help and the installation time is faster as compared to other types of rivets.

Blind rivets can be used to fasten metals, wood, and even plastics. They can even fasten two different materials together. For all these advantages blind rivets are majorly used in the manufacturing of boats, aircraft, and other vehicles.

Blind Rivets

3)  Split Rivets

Split rivets are commonly used to join softer materials such as wood, leather, and plastics. While using, split rivets are pre-split along the length of their shaft due to which two legs are formed.

Upon installation, these legs fold back which helps to hold the joined materials together. As they are used to join softer materials, split rivets are mainly used in the industries that produce clothes and plastics. Split rivets also find application in the households to carry out basic home-repair activities.

Split Rivets

4) Drive Rivets

Drive rivets have a small protruding mandrel from the head. A major USP of drive rivets is that the holes do not require to be drilled all the way. Thus, they can be used with plastics, metals, and even other materials without a need to use specialized tools.

All one needs to do is drive the mandrel end of the drive rivets into the hole Installing a drive rivets requires very little force hence it is used in household works such as securing a nameplate.

Drive Rivets

5) Tubular Rivets

Tubular rivets have a manufactured head on one end and the other end is hollow. Thus, these are partially hollow rivets and the hollow end requires cold forming. They find applications where the joints need to be movable.

Tubular Rivets are further classified into the following types:

  • Compression Tubular Rivets: It consists of two parts, a stem and a cap that fit together. These are most commonly used in the clothing and textile industry for joining and fastening purposes.
  • Semi-Tubular Rivets: Semi-tubular rivets are unique as they have a hole at the end of the shank. Installation of semi-tubular rivets requires a pre-drilled hole.
  • Full Tubular Rivets: These have a deeper hole as compared to semi-tubular rivets and are majorly used to fasten hard and soft materials together. It is less damage-prone as compared to other rivets.

Tubular rivets are made with materials that are lower in strength and are majorly used for commercial purposes.

Tubular Rivets

6) Threaded Rivets

The interior portion of a threaded rivet has a threaded stem while the external portion is machined flat on two sides. This feature allows the tool to grip and rotate it. The head is hexagonal which prevents the body from rotating while the mandrel bends and breaks off.

Threaded rivets can be installed in any material and are used when the installation is possible from only one side. Threaded rivets form a solid foundation to screw in bolts or other fasteners and thus these are ideal for mass installation purposes.  

Threaded Rivets

7) Oscar Rivet

Though oscar rivets appear very much like blind rivets, they are divided by a hollow shaft. In oscar rivets, the mandrel is pulled into the rivet which results in a split and causes the shaft to twist in and out. This property of oscar rivet minimizes the chances of wearing out. The unique design of the oscar rivet is ideal for high-vibration applications.

Oscar Rivet

8) Flush Rivet

A flush rivet, also known as a countersunk rivet, is used primarily on external metal surfaces to make them appear good. The sleek and smooth design of the flush rivet makes it an ideal rivet that is extensively used in the manufacturing of aircraft.

Flush Rivet

9) Friction-Lock Rivet

The blind end of a friction-lock rivet can be flush or dome-shaped. These are very much similar to expanding bolts, except that the shaft snaps below the surface when the tension is high enough. These are majorly used in the aerospace industry.

Friction-Lock Rivet

10) Self-Piercing Rivet

Compared to other rivets, self-piercing rivets do not require a drill or punch holes to be used. These are also semi-tubular in shape and have a partial hole at the opposite end of the head. The design includes a chamfered poke that helps this rivet in piercing the materials being joined.

While the self-pierce rivet can completely penetrate the top sheet material, it only partially penetrates the bottom sheet. As a result, a low-profile button is created when the rivet tail flares and gets interlocked into the bottom sheet under the influence of the upsetting die.

Self-Piercing Rivet

11) Pan Head Rivet

Uniquely designed, pan head rivets have a slightly rounded head sloping down from the top of the head. This helps them to provide a tighter grip during the fastening process. Pan-head rivets are used in heavy-duty based industry as they provide maximum strength and grip.

Pan Head Rivet

12) Mushroom Heat Rivet

As the name implies, they have heads like mushrooms. A mushroom head rivet is used to place the rivet head height on the metal surface which in turn provides the locking needed to hold the material strongly and securely.

Mushroom Heat Rivet

Thus, rivets are a widely used fastening material in the manufacturing world. Rivets are superior to other fastening materials such as nuts and bolts in terms of durability and flexibility. When compared with the welding process, the riveting process is cleaner, quicker, and a lot cheaper.

Rivets are versatile in the sense that they can fasten not only metals but also plastic. They can even fasten two different materials together. Today, rivets find application in various industries such as aerospace, construction, fashion, and others owing to their superlative features, it being cost and maintenance effective, and properties such as strength and durability.

Rivets come in different materials such as plastic, steel, copper, and also different types ranging from blind rivets to split rivets to cater to a wide range of industrial and manufacturing requirements. Using rivets also saves manufacturers the cost and effort in the maintenance of the materials. It can be concluded that rivets truly are the backbone of the manufacturing industry.

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CNC Machining Brass:Everything You Need to Know

cnc machining

Introduction

Brass is an important copper alloy with many useful properties, high machinability being one of them. It is being used widely in all kinds of CNC machining manufacturing machines, particularly in CNC machining. Currently brass is CNC machined to make many types of components such as wires, brass gears, prototyping, 3D modeling, musical instruments, furniture and much more.

This article discusses the use of brass in CNC machining, different alloys, their properties, and finally, the advantages. Let’s get into it.

Brass – An Overview

Brass is basically an alloy of copper and zinc including minute proportions of other elements like silicon, arsenic, manganese, aluminum, and magnesium. The percentages of copper and zinc are varied to make different alloys of brasses with different appearances and properties.

Bronze is often confused with brass due to its similar appearance, but bronze is an alloy of copper and tin and bears different properties.

All brasses are highly ductile and malleable. They can be easily shaped, formed, and cut into complex shapes and parts. Musical instruments and jewelry are examples of how brass can adopt any shape with ease.

cnc machining

Due to its golden and shiny appearance, brass is used in many decorative elements, household utensils, and jewelry. Its high thermal and electrical conductivity makes it prevalent in applications such as wiring and bullet shells. Combined with high corrosion resistance and low friction, it is widely used in the making of gears, doorknobs, hinges, valves, and other fittings.

In addition, brass offers a unique anti-bacterial property that lets it kill certain types of bacteria when they come in contact. This is paving way for brass to be used in marine applications such as ship hulls.

Can You CNC Machine Brass?

Yes. Second to aluminum, brass is highly prevalent in CNC machining due to its excellent machinability. Compared to aluminum that sticks to the machine during machining, brass chips do not stick. The tool retains its sharpness and efficiency in brass machining.

Due to their good hot and cold formability, these alloys are extensively in industries for making screw machine parts, gears, fasteners, marine hardware and components, pump shafts, etc.

Brass is 100% recyclable. This makes it highly cost-effective and energy-efficient in CNC machining.

What Are the Benefits of CNC Machining Brass? 

The main component of brass is copper. So, many of the benefits of copper are directly inherited by brass. Copper is a softer metal with excellent shear resistance. Brass maintains most of this shear resistance and gains high tensile strength from alloying with other metals.

Following are a few benefits for CNC machining brass,

Efficient Machining

The high tensile and shear properties of brass make it excel at high-speed machining. High-speed machining can result,

  • The workpiece heating up
  • Large chips forming
  • Distorting or cracking in rare cases.

Brass is a softer metal that is easier to cut. Thus, it is resistant to all of the issues mentioned above. Machining at high speeds shortens the cycle for parts manufacturing. Making the overall machining process incredibly time-efficient. Moreover, brass machining has no negative impact on the machine itself. The tools do not get damaged due to sticky chips. On the other hand, chips fly away making the cleaning easier and fast.

Precise Machining

Brass has good impact resistance and thus higher deformation resistance. These resistances allow for brass to maintain its dimensional accuracy after machining.

So, if your manufacturing requirements involve strict tolerances such as applications of gears, valves and bullet shells, brass is a great option.

Brass Alloys

Brass isn’t limited to a single use-case. Brass is an alloy with a wide range of grades commercially available. Corrosion resistance, strength, formability all can differ based on the brass grade.

For example, Brass C35300 has excellent corrosion resistance. But Brass C86200 has excellent strength.

The versatility of these grades further adds to the benefits of Brass machining.

Brass Tooling

The tools required for a CNC machine depend on the material of the workpiece. Harder workpieces need stronger cutting tools. As brass is easier to cut, its tool compatibility is high.

Easier to cut metals also cause far less wear and tear to the tool. Thus, a single tool can machine for a long time without being replaced.

Tool and tool maintenance costs are reduced when you’re CNC machining brass.

Cost-Effective Machining

Brass machining is more cost-effective because of all the previously discussed benefits. You will spend less time matching brass. End up with precise dimensions, and save a lot on tooling costs.

What Are the Drawbacks of CNC Machining Brass? 

Brass has little to few drawbacks when concerned with machining. The majority of the shortcomings of brass are related to the material itself.

Oxidation

Brass can oxidize easily, causing a blackish coloring in the metal. Most brass products need to be lacquered after machining to prevent oxidation. But with time, the lacquer will wear away.

Thus, you will need to lacquer every part you make using brass. Additional time is spent applying lacquer, reducing the initial efficiency of brass machining.

Corrosion

Most brass alloys are fairly corrosion-resistant. But since the base metal for brass is copper, it is susceptible to water damage. Corrosion can make storing brass a hassle.

Season Cracking

One another disadvantage of brass is the occurrence of stress corrosion cracking. It is highly susceptible to cracking in an atmosphere having ammonia.

What Is Unleaded Brass?

Despite the naming, unleaded brass does not mean zero lead content. Unleaded brass must contain less than 0.25% lead. This is opposed to the 8% typically used in brass alloys.

Unleaded brass is defined in the “Reduction of Lead in Drinking Water Act”. Though this is an American bill, manufacturers of brass alloys use this to label their products as “unleaded” or “lead-free”.

Is It Easy to CNC Machine Brass? 

Yes, brass is easy to machine, especially when compared to other metals. Brass is often alloyed with lead, a much softer metal. Since lead also has a lower friction coefficient, it produces less heat when machining. Allowing brass to be easily machined at high speeds.

Leaded Brass is very beginner-friendly. Since it has less tool wear, brass can be forgiving if the feed is incorrect. Novice operators may want to try machining brass before difficult metals like steel.

But if the lead is responsible for easy machining of brass. Then what about unleaded brass?

No, Unleaded brass is not easy to machine. By decreasing the lead in brass, it becomes harder. Which will result in an increased friction coefficient for the material. More friction means more heat and more tool wear. Unleaded brass alloys also produce longer and string-like chips.

Machining unleaded brass requires coolant for friction heating. And constant monitoring and management of metal chips.

Brass itself is still an excellent choice for machining. But depending upon the application, unleaded brass may be required. So, you must take extra precautions when selecting the right brass alloy for machining.

Uses of Brass 

Brass can be used for several applications because it possesses both mechanical properties as well as an attractive appearance. Brass applications can be divided into two categories,

Aesthetic – Polished brass has a bright and shiny finish. It also bears a striking resemblance to gold. Making it desirable for decorative applications. 

Functional – Brass has good corrosion resistance and a low friction coefficient. Making brass an excellent metal for technical applications.

Following are a few common use cases for brass,

  • Musical Instruments – Trumpet, horn, tuba, etc.
  • Plumbing Equipment – Pipe, faucet, fittings, etc.
  • Ammunition Casings
  • Precision Instruments – Watches, barometers, locks, etc.
  • Decorative Furnishing – Handles, Trims, rivets, etc.
  • Underwater Applications – Radiators, Coating for ship hulls, etc.

Popular Alloys of Brass for CNC machining 

Brass alloys used in CNC machining are all application-based. When selecting a suitable brass alloy, you should consider your desired properties.

Following are a few popular brass alloys commonly used in CNC machining.

Table 1 Brass Alloys

cnc machining

Some brass alloys are also called “Bronze” in the industrial sector. These are brass alloys that are given names based on their appearance.

Final Words

We have everything you need to know about the CNC machining of brass, its uses, the difficulties to address, and its advantages.

Now that you know the benefits of Brass in CNC machining let us carry out your brass jobs with high precision and unmatched efficiency. Take your brass projects a notch higher using our expertise in machining all materials. QBH has a team of CNC experts having a lot of experience in brass CNC machining.

Other than brass, we can perform CNC machining on many different metals including stainless steel and aluminum. We can perform high precision CNC axial milling (3,4 or 5 axis milling), sheet metal fabrication, and offer postproduction services. QBH is always willing to discuss your projects, brainstorm solutions, and help you decide what is best for your projects. Call us anytime!

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Aerospace Fasteners: Understanding Types and Materials

CNC Machining

Saying that fasteners helped us conquer the space would not be farfetched. In fact, Aerospace Fasteners are pivotal to the aviation industry and have revolutionized traveling.

Nowadays, we see bigger and faster air and space crafts which were only possible with modern Aerospace Fastener technology that holds the body together, even in extreme atmospheres and vacuums.

Here we have arranged a detailed guide that goes through all the aspects of Aircraft Fastener manufacturing.

Let’s go!

Aerospace Fasteners- An overview

Components like screws, rivets, bolts, nuts, etc., keep the integrity of the pressurized vessel in the atmosphere. They are an integral part of the aviation industry which means a lot of engineering and research goes into these fasteners.

Maybe you run a fastener manufacturing business, or an aircraft technician, or just an aviation enthusiast; nonetheless, we have compiled a great deal of information for you. Let’s get into it.

Types of Fasteners used in the Aerospace Industry

Fasteners are a vital element of any aircraft. Unlike most other vehicles, aircraft parts cannot be welded or glued together. Aircraft use different materials for different sections. Not all of these materials are weldable. And using glue or adhesive is not feasible for such precision work.

It’s the job of fasteners to connect these parts precisely with one another. Precise joints require precise fasteners. Types of fasteners are varied and numerous. They are based on standards like AS9100, AS9120, BS9100, etc.

The aerospace industry uses the same fasteners as other industries. But to maintain strict tolerances, they follow specific ISO standards for aerospace fasteners.

Here is the list of fastener types that are commonly used in the aerospace industry:

  1. Screws:

Screws are the most common and practical threaded fastener available. It has various types such as Hex Cap, Cap Head, Security Screws

  1. Pins

Dowel Pin are small cylindrical shafts used to arrange or join two or more engineering components together.

  1. Rivets

Rivet- a permanent fastener often seen on the aircraft body. It has a shaft and the head installed using a rivet gun and holds two pieces together.

  1. Bolts and Nuts:

Another threaded fastener with excellent grip. It comes in many shapes and sizes, such as Hex, Head, Eyebolts.

  1. Washers

Not precisely a fastener itself, but it aids aircraft screws and bolts in preventing vibrations and distributing the load over a larger area.

  1. Collars

Collars also aid bolts and screws in locking the two components effectively.

  1. Fastener Covers

Made from strong material and used for protecting the fasteners from external impact. Making it long-lasting and maintenance-free.

All these fasteners must adhere to specific standards. Here is a brief list of common ISO Standards for aerospace fasteners.

Aerospace Fasteners

Specialized Aviation Fasteners

Apart from the common types of fasteners mentioned above, several specialized ones are designed specifically for aerospace use. These aviation fasteners high higher strength and less weight. Some of these are as follows:

Taper Lock

The most robust of all fasteners, Taper-Lock has a tapered shape that applies force on the hole’s wall. Different than rivets, the shank is not deformed when it is fixed.

Taper-Lock’s washer head presses itself in the tapered shape hole with extreme pressure. The shank experiences radial and vertical compression from the washer and the wall, creating a strong lock with the greatest strengths.

Hi-Tigue

Hi-Tigue has two parts. A fastener and a bead. The bead squeezes against the wall preloading the hole. The preloading prevents vibrations and cyclic loading, making it an essential fastener.

Turnlock

Easy to use, fast action, and a strong fastener-Turnlock. It is used to fasten aircraft panels, doors, hatches, etc. It has a spring, a stud, grommet, and receptacle. Usually made up

Spacecraft Fasteners Vs. Aircraft Fasteners

Aerospace fasteners come in two categories. Spacecraft and Aircraft both fly in different atmospheric conditions, which means their requirement for a strong body is different.

Spacecraft fasteners have more tensile strength than commercial grade fasteners because they have to withstand a vacuum in space. Here are some stats to get an idea of how high-performance aerospace fasteners are:

Material Used in Manufacturing Aircraft Fasteners

Selecting a suitable material is the first step in manufacturing. Material selection depends upon the application. It is essential to consider factors like strength, weight, heat/electric insulation, corrosion, and rust resistance beforehand. Following are a few commonly used materials in CNC machining,

  1. Steel & Steel Alloys

Probably the most versatile and practical material of all, steel. It’s robust but comes with a heavy weight.

  1. Aluminum

Super light and malleable, used for many fasteners. But it is less heat resistant and can melt at 250℉ (120 ℃). Aluminum and Steel are more common for load-bearing joints.

  1. Titanium

One of the strongest metals to exist on the planet and excellent for aerospace fasteners. Lightweight and have high tensile strength. They can withstand -212℃ (-350℉) to 426℃(800℉).

  1. Plastics: Nylon, HDPE, or PVC

Plastic fasteners are only helpful in aerospace applications when strength is not a concern. Plastics like Nylon are resistant to corrosion and electrical interference.

  1. Super Alloys

Super Alloys-combining the strength of multiple materials, they usually have higher material properties than their constituents. They can withstand extreme temperatures and large stress.

Characteristics of Aircraft Fasteners

Aerospace fasteners need to have specific characteristics to survive extreme conditions. Their features are enhanced by special designs, performance-enhancing techniques like “Heat Treatment,” advanced composites, etc.

Here are some important inherent characteristics of Aerospace fasteners:

  1. Corrosion and Oxidation Resistant
  2. Self-Locking
  3. Lightweight but High tensile strength
  4. Can resist high shear stress and cyclic fatigue
    Aerospace Fasteners

Why is CNC Machining Important for Aerospace Fasteners?

The aerospace industry requires high-performance machines. As such, they need the utmost care when manufacturing. A single mistake can compromise the integrity of the entire product. Aerospace machines like Aircraft have hundreds of thousands of parts perfectly joined together into a single device.

For example, The Boeing 747 is composed of 6 million parts. And 3 million of those parts were fasteners, which means 3 million potential points of failure.

All of these parts must maintain a strict tolerance. This precision can only be achieved using computers. CNC Machining solves this exact problem, allowing for unparalleled precision and accuracy.

Benefits of using CNC Machining for Aerospace Fasteners

CNC Machines allow for a wide range of advantages over traditional machining. CNC machining allows,

  • Machining difficult materials. Titanium or steel alloys.
  • Weight Reduction. By precision manufacturing of complex designs.
  • High accuracy. Precision is getting the exact dimensions. Accuracy is getting the same precise results upon repetition.
  • Extremely efficient manufacturing. High-speed machining in less time.
  • Customized manufacturing of non-standard or purpose-specific parts.
  • Rapid prototyping.

Conclusion

To conclude, aerospace fasteners are critical components, and their efficiency can be a matter of life and death in space. These components hold the pressurized vessel together and prevent any leakages. We have covered extensively the types and materials of fasteners used in the aerospace industry. Also touched is the subject of CNC Machining and its importance in manufacturing high precision fasteners for the aerospace industry.

QBH Technology offers rapid CNC manufacturing services for Aerospace Parts and Accessories. Our state-of-the-art facility is run by experienced machinists and engineers who deliver high-quality products in the shortest lead times.

Get the best service and an opportunity for custom designs RIGHT NOW!

Drop us a message, and our FAST customer service will contact you in no time.

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How to Avoid Mistakes When Designing For Manufacturing?

manufacturing

Designing for manufacturing is a difficult task. It needs full attention, consideration, and expertise, and you have to give much time to think and finally manufacture beautifully designed products. If you don’t design suitable products for manufacturing, it wastes both your time and money.

So, it is important to consider various aspects while designing the products for manufacturing. It will provide you with your desired products and save you energy, time, and money. While designing for manufacturing, some mistakes are very common, and it is very important to avoid them. Following are some ways by which you can avoid making mistakes while designing.

1.By Taking the Proper Information and Knowledge about the Machinery

The lack of proper knowledge and information is one of the biggest mistakes you make while designing for manufacturing. You must have a detailed knowledge of your machine’s limitations and working ways. If you don’t have proper and whole information about your machinery, then you cannot design it properly, and it is just wastage of time to manufacture it. Having proper information helps you design and avoids mistakes when designing for manufacturing. So try to get in touch with the latest news and discoveries to know the basic demand and trends of the manufacturing market.  

2.By Permitting the Aesthetics to Hinder Manufacturing Unreasonably

You can avoid mistakes when designing for manufacturing by allowing the aesthetics to hinder unnecessary manufacturing. It is necessary to avoid making heavy aesthetic features difficult to handle during the manufacturing process. Similarly, other factors that are not much important should be neglected while designing. While designing, manufacturing heavy, intricate, and unnecessary aesthetic features is the biggest mistake. It will allow the machinery to work improperly and waste time and money.

So it would help if you tried to skip these features while designing for manufacturing to make more valuable products.

manufacturing

3.By Using Feature Sizes and Non-Standard Material

You can avoid mistakes in manufacturing by using non-standard material and features sizes when designing. You should use a non-standard material to design your machinery to avoid mistakes. Moreover, using a feature size tool in designing your machinery is also compulsory. For example, if you want to drill the holes in a part of the machinery, don’t use common drills. It may drill holes that are larger or smaller than the required sizes. So, it may cause defects in machinery. Always use standard sizes of tools while designing your machinery to avoid mistakes.

4.By Designing the Features that are Easy to Manufacture

The most common mistake that the manufacturer makes during designing the machinery is designing the very difficult features to manufacture. Sometimes you may choose difficult and complex designs to manufacture the machinery, but it’s better to avoid unnecessary intricate and complex features and designs. Designing such complex features may take much more time and energy. You may also fail to design such features because they are impossible to manufacture, failing your designing process. It would be best to use simple designs that are easy to handle and function properly. During the manufacturing process, you should also use features that are not easily breakable so that your machinery can work properly for a long time.

5.By avoiding Tall and Thin-walled Material

The biggest mistake you should avoid during the designing process is tall and thin-walled material for designing different machinery parts. The thin-walled parts may bend when little force is applied to them. It may also cause the breakage of the machine parts, resulting in machinery breakage. You should use thick-walled and rigid material while designing the machinery. The thick-walled rigid material doesn’t break due to the applied force. Moreover, the machinery made with such material is more reliable and works longer than the thin-walled material. Avoiding this mistake can avoid both your time and energy.

manufacturing

6.By Avoiding the Small and the Raised Text on Machinery

Adding text is also an important part of designing when manufacturing. The text can be in the form of a company logo, description, or a number or you may add the desired text of your choice on the component. The text on the machinery may look cool, but you should be selective about the size of the text you will add to your machinery. Most manufacturers think that adding a smaller text to your machinery costs less than larger text. But, it is not true. The smaller text means high cost. The small endmills cut smaller text. The small endmills work at a very low speed, thus taking more time resulting in a more cost. On the other hand, the larger text is cut down easily and quickly, thus reducing the cost. So, by avoiding small text, you can avoid mistakes when manufacturing.

7.By Avoiding the Features that Need Unnecessary Machining

The biggest mistake that the manufacturer makes in designing is the addition of features that require unnecessary machining. Adding unnecessary features results in extra material for designing and results in high costs. If you avoid adding such features, you don’t have to add extra material in designing the machinery. So, it saves both the material and the money.

 8.Lack of Consumer Research

Neglecting your customer advice is also among the biggest mistakes in designing the machinery.

Your customers’ choice should be your priority. You should have a complete idea of your customer’s choices and ideas. Designing the machinery according to the customer’s advice will make your customer happy due to the exact design and prevent you from regretting it.   

 manufacturing

Final Thoughts

Mistakes and complex designs when manufacturing machinery are common, and you should avoid these mistakes. These mistakes in designing can lead to serious damage and loss of machinery. So, avoiding these mistakes is necessary to design the machinery perfectly and prevent any loss and damage. The ways mentioned above help you prevent these mistakes and prove helpful in saving your time, energy, and money.

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Types of Fits: How to Choose the Right Fits in Engineering

Rolled Steel

You must bring diverse processes together to achieve a shared goal in production. When we make a system component, we need to think about how we will use it, where we will use it, and its dimensions. We (QBH Technology) create our goods on that basis. As with sorts of fits, we can examine how they relate to various components.

What Do We Mean By Fit?

There must be a fit between the hole and the shaft for proper installation. We can gauge the degree of tightness or looseness between two components with fits. As a result, it’s a two-component connection.

The clearance between two mating parts determines the size of the engineering fit when apart, and many other components are being developed as geometrical dimensions.

Fits have defined the phrase as a “shaft and hollow” in engineering. So, the degree of freedom of tightness between two mating components is defined like this: Comparing two shoe types, such as running and sliding, Take a look at this example: we have two holes and a shaft.

We build the shaft to slide into the hole in the same sliding feet.

Fits

Smallest and Largest Hole and Shaft!

The following information will help you determine the smallest and largest diameters of the shaft and hole:

  • We have the smallest and largest limit for holes and shafts. · The shaft’s smallest diameter or smallest diameter is meant by the term “smallest limit.” the term “largest limit” refers to the largest diameter or, in other words, the largest possible length of a shaft.
  • We may adjust the hole and shaft dimensions from the smallest to the largest.
  • Adding material to a hole enlarges it; hence the term “greatest limit” refers to the amount of material that can be removed from the hole before it reaches its largest size.
  • When we talk about the hole’s minimal limit, we refer to the largest amount of material that can fit within.
  • Because the hole and shaft are arranged in such a way that they face one another.
  • For shafts with minimal material, the shaft’s size is also minimal.
  • In contrast, the greatest amount of material exists in a hole in the “smallest limit,” and the greatest amount of material removed from a hole is the “largest limit.”

What Are The Different Types Of Fit?

In manufacturing and mechanical engineering, there are three main forms of fit.

Type#1: Fitting Clearance

When unfettered mobility and some degree of playfulness are needed, clearance fit matings allow for a looser fit. A clearance fit is called for when elements need to slip in and out or when alignment may be guided but does not must extreme accuracy.

Type#2: Fitting Interference

It is far more difficult to fit interference than a clearance fit. The interference fit, also known as a press fit or friction fit, requires some degree of force to unite two components.

We can use an interference fit to press a bushing, bearing, dowel pin, or another object into its mating components.

Type#3: Transition Fit

There are two kinds of fits: clearance and interference. Transition fits are required when we must achieve precise alignment and matching components. These are sometimes known as a slip or a push-fit. Although the clearance is more than a press/interference fit, it is narrower and should drop any extra joint play or movement.

Finding the Right Fit for Your Project!

To select the best match for your tasks, you must first grasp several concepts. Here are a few things that we (QBH Technology) researched for you to keep an eye out for:

1. Application

Various options are available if you’re looking for a certain sort of fit for a specific reason.

Choosing the ideal fits for a project should be as simple as comparing the accuracy and tolerances displayed by various types of fits and the planned function of the product.

2. Budget

You should know your budget before choosing the best forms of fit for your merchandise. Fits with tighter tolerances, for example, will be more expensive than usual.

As a result, you must consider your alternatives. You are getting a fit that reduces product development costs while delivering the necessary tolerance.

3. Tolerance

Product tolerance is a notion that we must grasp to select the right fit for a certain product. The more detailed you are, the more likely you will get what you desire.

Besides, it would help to decide whether the parts should revolve in a complete circle or be tight.

Tolerance slack, or the entire largest or lowest tolerance of a specific measurement, is something else to watch. If the resultant tolerance is high, this is critical.

fits

When to Use Press Fits in Assembly?

I may be talking about your favorite pair of jeans or a press-fit that adapts to every environment. It keeps pieces in perfect alignment, is simple to introduce, and forms a strong link.

Press-fit connectors offer so many advantages that you may ask why they aren’t used for everything else.

There are advantages and disadvantages to interference fittings, as there are press fits (unlike skinny jeans, press fits will never go out of style).

In other words, what are the most important characteristics of press fits, and do you need them for your particular use case?

▬ No Plastic Press Fits

Press fittings rely on friction and continual tension. If you press a large pin into a hole in steel, it will stay there forever. Under persistent pressure, plastic will flow, and the tension, and the friction it causes, will finally evaporate. Wearing jeans to a black-tie event is like wearing sneakers to a black-tie event.

▬ Using Interference Fit to Calculate Force

Here, let’s look at press-fit techniques in a more positive light. As before stated, the assembly technique is predicated on two elements competing for the same amount of space. But, the question remains: How much meddling is too much? Take a look at how your jeans fit this time: its okay if it’s a touch tight, but if it’s too tight, you risk appearing like Justin Bieber.

The “Beliebers” may want to take note.) Skip to the end of the article if you’d like to. (I have nothing to impart to you. We know how tight the interference fit should be, unlike jeans. Dowel pins will make our calculations a lot simpler. But how can you determine if the interference is enough to hold the pieces together?

For the time being, let’s create a mental model and then go to the formula. Pins and holes both strive to restore their previous diameter when inserted into a hole. The pin tries to press outward, while the hole tries to press inward. The typical force created by the friction between the two pieces helps us determine how much of a grip we’ll get.

Look at a half-inch diameter steel dowel pin inserted one inch deep into a steel plate for a realistic illustration.

Because it’s a national number, I’m not sure why a half-inch hole is nominal since the pin is somewhat bigger and the hole is smaller.

Half-inch pins in the standard series have a diameter of 0.5002 inches, two-tenths of an inch larger than normal. We get 0.0007 inches of diametrical interference with 0.4995-inch smallest hole-size. That may sound insignificant, but as you’ll soon discover, it’s a lot.

▬ Restrictions on Tolerances and Alignment

A small amount of interference may have a huge impact. Also, to hold your pieces together, the axial holding force is needed to assemble them. You risk damaging the hydraulic press if you don’t define press fittings. It would help avoid press-fitting for ordinary industrial assembly because of this tight machining tolerance—it isn’t DFM/DFA friendly.

To determine the smallest and largest holding force and assembly force for different hole diametrical tolerances, you may use the calculator found here.

But, the diameter isn’t the only factor to consider. Because pins are sold in pairs, keep in mind how far apart the pins are from one another.

▬ Thermal and Material Constraints

Every substance shrinks in the cold, although the pace at which this happens varies. To illustrate, imagine that you’ve used a 1-in aluminum pin to fasten together two-in stainless steel parts with a diametrical interference of 0.0007 inches.

CNC aluminum will shrink 0.0000125 in/in for every degree Fahrenheit, whereas steel shrinks by less than half of that amount; this is based on the linear expansion coefficient of the two sections.

At 75 degrees, you’ll lose all the press fit’s holding force if you move it down to 25 degrees below zero. As a result, create press fittings; choose materials with equal thermal expansion.

▬ Excessive Restraint and Alternate Joints

Press fitting’s plain strength—their ability to identify and join—is a flaw. A machinist can’t dimension to the thousandth of an inch since the two functions are intertwined and cannot be calculated (or to the micron, for those across the pond).

Please don’t give up hope, even though journalistic protests have limits. There are a plethora of contemporary design options.

Alignment and assembly in plastics are facilitated by locating pins and snap fittings. A few brief examples, but mechanical assembly choices are infinite.

 fits

Final Thoughts

It isn’t effortless to use different fit types and put them to use in various mechanical applications. After reading this article, you’ll have complete knowledge of a fit and its multiple sorts.

Choosing the proper people for your projects starts with doing your homework, and this article explains how to do that. What a fit is and how to use it are not the same.

While this tutorial will teach you design fundamentals, outsourcing to the right company can help you stand out from the crowd.

At QBH Technology, we are in the best position to meet your needs in terms of quality and pricing. Your product’s quality will soar far above your competitors’ when you work with us.