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Chirag

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Chirag is a Lean Manufacturing Engineer who has been in the tech industry his entire career. He is the founder of Lookmanufacturing and he is passionate about the development trend of the industry. That is why he created this Industry and design blog.

CNC

Ultimate Guide to Purchasing the Right Press Brake

by Chirag
written by Chirag

A press brake is important CNC equipment. As a manufacturer, you want to ensure you get a machine that suits your applications. Before you purchase the cnc press brake, you need to understand different aspects, such as precision, processing range, performance, and function of the machine. You should note that a press brake is a significant investment and if you buy the wrong one, then your production costs are likely to increase. These are the critical things that can help you make a sound decision.

Parts You Produce

You have to buy a press brake that can do the finishing task, rather than getting one with minimum tonnage and shortest worktable. Ensure you check the steel sheets available plus their length and thickness. For instance, if you are using low carbon steel, then you do not need a lot of bending force. Another critical thing you should consider is the length of the material.

Deflection

When bending a long workpiece, you need a CNC press brake with deflection. The length of the workpiece should be directly proportional to the deflection. A shorter press brake with minimal gasket adjustment is needed to create qualified products. Some press brakes have hydraulic deflection, which helps reduce the machine adjustment.

Material Texture

If you are using low carbon steel, then the bending force ought to be increased by about 60% of the stainless steel bending force. However, if you are using soft aluminum, then you need to reduce the bending force by a similar amount. The press brake manufacturer can provide you with a bending pressure parameter. Also, you need to take into account the bending angle radius. If you are performing free bending, you should consider the clearance between a die and punch.

Type of Press Brake

When buying a press brake, you ought to know the type of machine you want. In this way, you can determine whether this is the best fit for your shop or not. The common press brakes are CNC, hydraulic, servo, mechanical, and hydraulic. You can find some with a combination of different mechanisms.

Hydraulic press brakes are common because they can handle heavy loads and are easy to use. If you are dealing with thick materials, this is the perfect press brake to suit your needs. However, if you want an energy-efficient press brake, then you should consider the electronic press brake. Other than being energy-efficient, it is easy to fix and maintain. Also, it has higher accuracy than the hydraulic one. You will find this machine available in different sizes to suit various applications.

Select Right Tooling

The tooling you require depends on the various types of materials the shop works with. Ideally, you need tooling that offers you the best tooling profile. You should ensure you do not exceed the required press brake loads or tooling. If you want to use the tooling with the press brake and ensure it is in the right condition and compatible. Look out for wear marks from punches to shoulder.

Find a Reputable Press Brake Manufacturer

It is advisable to find a reliable CNC press brake supplier or manufacturer. Usually, manufacturers have experts who can help you get the right machine to suit your needs.

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Industry

Why the plasma metal cutting machine is so popular

by Chirag
written by Chirag

Plasma metal cutting machine dates back to the 1960s. It is a high-tech process that ionized gas with very high velocity to cut through electrically conductive materials such as metal sheets, aluminum, stainless steel, brass, copper, nickel, etc. The ionized gas is also known as plasma. This is after all, what the machine uses as a source of heat.

Unlike oxy-fuel cutting which cuts through metal by burning or oxidizing it, plasma cutting is not reliant on oxidation and can be used on non-ferrous materials that are usually resistant to the oxy-fuel method. The plasma cutting method is very precise and has a relatively higher velocity compared to other methods of cutting metal.

As a result of its efficiency and low cost, plasma cutting is widely used across industries ranging from industrial CNC applications to small shops where their materials are often welded. A plasma cutting machine can cut through thin metals and metals as thick as 3’’. They are widely recognized for their quality, velocity, and versatility.

The process

The plasma cutting process is a thermal cutting process. The gas is heated up to a temperature above 20,000°C which forms an electric arc between the workpiece and an electrode. The electrode is securely placed in a gas nozzle cooled by air or water which contracts the arc to form a narrow, accelerated, high-temperature stream of plasma.

As a result of ion recombination, immediately the plasma jet strikes the workpiece heat is transferred which causes the gas to return to its initial state. The metal is melted by the transferred heat and the stream of gas blows away the molten material through the cut. All through the process, the surface surrounding the area being cut stays cool. As the plasma cutting machine travels along the surface, a neat, linear cut with little or no slag is produced.

Plasma cutting machine can be used in industries such as automotive repair and maintenance, shipyard manufacturing, construction sites, fabrication, etc.

Advantages of plasma cutting machine

  • Safety

Plasma cutting machine is very safe to use especially since it uses inert gases that are not flammable thus getting rid of the risk of fire hazards associated with gas cutting procedures.

  • Increased cutting speed/velocity

Plasma cutting machines do not just cut material effectively but quickly as well. They require less than the time often used by other cutting methods.

  • Minimal slag or dross

Slag or dross on the material is commonly associated with materials cut with oxyfuels. This problem is eliminated when the plasma cutting machine is used. It leaves no little or no slag on material after they are cut.

  • Precision

Plasma cutting machines are widely known for their precision. They can be used to draw curves, multiple cuts that are intersected by a precise beam.

  • Versatility and compatibility

The plasma cutting machine is very versatile and can be used on a wide range of materials such as aluminum, copper, steel, titanium, nickel, iron, sheet metal, brass, etc.

  • Cost-effective

Plasma cutting machine is very economical and cost-effective. It requires low maintenance and it is less expensive than other forms of cutting machines water-jet or laser cutting.

Conclusion

Plasma cutting machines are not only compatible and versatile, they are quite portable and would give one value for their money.

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Processing

How rotogravure printing cylinder works

by Chirag
written by Chirag

Printing has gone from the traditional way of imprinting colors on substances with the use of perforated carton papers, paints, and brushes. The rotogravure printing cylinder is one of those amazing developments in the printing press. As a printer—beginner or expert—, who wants to enjoy a smoother and easier work level, this is a system you should know.

This article will show you everything about the rotogravure printing cylinder, how it works, the benefits of using it, and the kinds of materials you can use it on. Follow through the article for enlightenment.

What is a rotogravure printing cylinder?

A rotogravure printing cylinder is a printing tool that has been around for ages and has enjoyed tons of improvement and upgrades, used for retaining different pigments of ink for painting. The ink is held on to the cylinder with the use of tiny cells that expel the ink onto the substance on which the printing will be done.

The rotogravure printing cylinder has been around for years and has been used by several professionals and big names in the industry. Based on the advancements in the printing world, it is not becoming an even more accepted way of printing on thicker surfaces. Let’s take a look at the process.

How rotogravure printing cylinder works

The cylinder serves as the printing plate in other printing styles. With the rotogravure printing cylinder, the photo that is to be printed is etched onto the cylinder with a certain kind of acid. This photo is etched onto several cylinders in a pattern of cells. Each cylinder carries a different color but the same picture. When these cylinders are pressed against the substrate, they create an exact representation of what was etched on to the cylinders.

One thing you need to take your time with is the precision of the cells’ dimensions. You have to make sure they are precise to the solution or product you want to have. You must note that the deeper the cells, the thicker the color you will have on your substrate.

You will fill just the cells up with ink and leave the other parts of the cylinder clean. If there’s an area of ink on the other parts of the cylinder, you want to ensure that you have it properly cleaned and scraped before you start printing, or you will end up with rough work.

When the cells have pressed on your substrate and have recessed, the cylinder rotates back to fill the cells up with more ink for more printing. The process is repeated until all the printing work has been completed.

Rotogravure should not be mistaken for photogravure, which is a much cheaper version and variation of gravure, involving etching the photo on a copper, which is then wrapped around the cylinder before the whole printing process begins.

Conclusion

Rotogravure has been in use over the years and is still one of the standing printing methods till today. I hope this article helps you to properly understand how rotogravure works.

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Uncategorized

Benefits of Using Soy Wax to Make Candles

by Chirag
written by Chirag

There are several reasons soy wax is used to make candles. For instance, this raw material is known to be eco-friendly, longer-lasting, and provides an excellent fragrance. The following are some reasons you should consider candles made from soy wax.

Eco-Friendly

You should note that soy wax is obtained from soybean oil. Since it is obtained from plants, it is a sustainable and renewable resource. On the other hand, paraffin wax is obtained from crude oil, specifically from gasoline refinement byproducts. Thus, it is sourced from fossil fuels, which are non-renewable. When you use soy wax, you support many farmers.

Remember that when you burn candles, the wax can spill. If that is the case, you have nothing to worry about, as the wax is biodegradable and can be cleaned by using basic water and soap. The problem with paraffin wax is that it not water-soluble or biodegradable. As a result, it makes the cleaning process quite tedious and time-consuming.

Clean Burning

You should note that soy wax does not produce any soot. Thus, it does not leave residue on the drapes, walls, and furnishings. Since this wax burns clean and it is non-toxic, it is considered to be safe for persons with allergies and asthma. The paraffin candles are known to produce petro-carbon shoots that can stain the walls, ceilings, and furniture.

Longer-lasting

Studies have shown that soy wax can burn longer than its counterpart paraffin wax. That is because it has a lower melting point and does not burn fast.

Great Fragrance Throw

The candle’s ability to release fragrance is what is called a throw. It can have a cold and hot throw. There are different things that have an impact on the fragrance throw. The petroleum base of paraffin means that it can emit a chemical-smelling fragrance. Since soy wax is obtained from natural sources, it emits a nice fragrance. Also, soy wax contains strong bonds that are difficult to break as compared to those of paraffin wax.

The flashpoint is considered to be the temperature that the fragrance oil can attain before it can break down. Thus, it varies from one candle fragrance to another. For instance, if the temperature is too high, the fragrance will burn off. You should ensure the fragrance oil bonds properly with wax.

Another vital thing to consider choosing soy wax candles is the concentration of the fragrance. If you are in candle making business, you need to follow the industry regulations. You should ensure you use a fragrance oil that is safe for the body and bath. It is recommended to dilute the fragrance oil before using it. Ensure you only work with fragrances that are recommended for soy wax. Remember that there are different variations of soy wax on the market. Each type has a different affinity to the fragrance oil. Ensure you follow the industry recommended ratio.

When you consider all these factors, you should consider using soy wax in all the candles. Other than supporting sustainability, you can also be assured that you are using a quality product that bonds with your favorite fragrances.

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CNC

Why Manufacturers Prefer CNC Machines

by Chirag
written by Chirag

Several decades ago, machinists were the talk of time and were responsible for crafting everything to perfection. Similar skills are still required, but when talking about producing a given piece on a large scale and with higher precision, nothing beats computerized machines’ superiority. That’s where CNC Machining comes in.

Following the invention of personal computers, numerical systems have penetrated almost every industry. Nowadays, custom CNC machining is an essential part of modern machining technologies. Unlike traditional machining, CNC machining involves the operator working with the main software in motoring machine tools as well as creating programs. Therefore, it’s easily said that CNC machining is an immense upgrade. So, what are the advantages of CNC machining?

Worker Safety

Unlike traditional machining, CNC machining has ensured that the worker’s safety is at the highest level. The operator is well protected from sharp parts by protective gear. Thanks to the glass, the operator clearly sees everything going on. Moreover, the operator is not necessarily required to get closer to the mill or spindle, or even anywhere close to the cooling fluids that could be dangerous to the skin.

Precise Machining

It goes without saying that CNC Machining brings the highest level of precision. With the machine, it’s very easy to carve out a product from material exactly as required. Therefore, it’s effortless to create a plethora of components with complex shapes within a short period.

Stable Replication Accuracy

You can’t think of something more stable than a proven computer program. Once the design is introduced into the computer, the machine is capable of repeating the manufacturing process over and over again.

Given that the precision is from the step-motors, it means that the movement is always similar, meaning you’ll always get the highest level of precision.

Labor Economy

In a nutshell, CNC machining improves automation. They require little attention once set in motion. The tools move automatically, with the operator only required to check whether there are errors in the setup or the program.

Therefore, there’s a lot of free time for an operator to be used on different tasks. The company can even retain fewer operators, meaning a lot is saved.

Flexibility

In the past, things were done differently in that a milling machine had to do planes or groves, drilling machines make holes, and a lathe to do tapers and cylinders. However, with CNC machining, all those tasks can be combined in a single machine tool.

Given the ability to program a trajectory of a tool, one is able to replicate any movement on any given machine tool. Therefore, the industry can be able to keep up with consumer demand.

Range of Materials

Another benefit of CNC machining is the fact that they can be used in the manufacturing of products from a plethora of materials. They include steel, bronze, polymers, and aluminum.

Fewer Test Runs

CNC machining has its way of avoiding test runs. For instance, it employs a visualization system to enable the operator to see what may happen to stock once all tool passes are done.

Together with minimum setup errors, the advantages of CNC machining are too many that manufacturing industries have grasped and are working to their advantage.

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