• CNC Machines
• CNC Machining
• What Do CNC Programming Services Do?
• CAD Design Process - CNC Process

• Lost Foam Metal Casting, Casting, And Metal Casting Information
• Metal Casting Tools And Definitions Of Metal Casting Tools
• Metal Casting Information And Basic Metal Casting Information
• Spin Casting, Sand Casting, And Other Metal Casting Processes
• Metal Casting Molds, Ingot Mold, And Cold Mold Information
• Casting Metal Hobbies, Home Metal Casting, Home Foundry Information

• Plastics Are The Best

• Machining And Keeping Your Shop Clean

• Injection Molds and Rotational Molds

Articles

CNC & CAD

CNC Machines

Submitted By: Stuart Simpson

What is a CNC Machine? CNC stands for Computer Numeric Control. Sounds complicated, but it isn’t. Years ago, it was just NC, or Numeric Control. Since, they’ve added computers to control the machine.

In the simplest of terms, think of a drill press. It’s a machine that drills holes. But before you can drill the hole, you have to loosen the chuck, install the correct drill bit, drill the hole in the correct place, turn off the drill, and remove the drill bit. Manually, this could be time consuming and cause fatigue over the course of numerous parts. This is a simple example, but throw in some lathe or milling machining and you have a greater chance for error.

With the CNC machine, all of this drilling can be done automatically instead of the manual process listed above. Machining has to be precise, and whether you use a CNC lathe or milling machine, you have to make sure the part is right. The computer takes a lot of the guesswork out of the machining of these parts. In fact, a CNC programmer can sometimes get bored watching the machine do all the work.

But there is more programming for the machine than you would think. The operator has to enter a set of instructions. The programming uses about 50 words and tells the machine how fast, how deep, and location for machining.

What can you do with a CNC machine? In manufacturing, you can use this tool for milling, drilling, reaming, boring and counter boring. You can also groove and thread parts in a CNC turning center. You may have several setups including CNC lathes, CNC drill and tap area, CNC milling, or even CNC grinding.

EDM (electrical discharge machining) can also take advantage of CNC operations. EDM can be either vertical or wire. A vertical EDM machine uses an electrode to make a cavity for a plastic injection-molding machine. A wire EDM machine uses a wire to cut metal for a tooling operation for fabrication. EDM is more closely related to making tooling for other machines, people often overlook the use of CNC with these machines.

CNC machines can also be used with routers in the wood industry. CNC can also be used with lettering and engraving.

I hope this gave you some basic information about what a CNC machine is and what they are used for.

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Article Source: iSnare.com

Everything before this topic is preparation. CNC Machining is where the rubber meets the road. All the steps of CNC before machining are just preparing for the machining phase of the project. A simple definition of machining is removing material. You remove material in various ways to come up with the part or piece.

CNC Machining can be performed on numerous types of material. For example, wood, steel, aluminum, and stone. Machining generally has higher tolerances associated with it. When machining, you are trying to do something more precise.

In machining, we use some sort of tool. This tool could be a grinder, drill bit, end mill, router bit or other tool. There are infinite variations of tools. CNC Tooling generally costs a fair amount of money. Once you invest in your tooling though, you can use it again and again until it wears out. If you have a large variety of different tools, you will be able to perform a large variety of machining types.

Here is a list of common tooling used in CNC Machines:

Drill bits
End mills
Plasma cutter
Dovetail cutter
Fly cutter

If you would like to look at different types of CNC tooling, go to one of these sources on the Internet:

Enco
Travers
McMasters-Carr
Grainger

Flip through a few of these suppliers’ catalogs and you will get an idea about the infinite styles of tooling.

CNC is used in the machining process. Generally, you can get better accuracy, quicker production, and overall efficiencies when utilizing CNC machining. This is why it has become so popular. In the past, CNC machining was very costly. Over time, it has become somewhat inexpensive and now people do it as a hobby. I am guessing that is why you are here.

Here are a few different types of CNC machines that perform various machining processes:

Milling machines
Wood routers
Plasma cutters
Foam cutters
Press brakes
Lathes
Cutoff saws

People have successfully applied CNC to virtually any type of motion control. The only thing that will limit you is your imagination.

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Article Source: iSnare.com

What Do CNC Programming Services Do?

Submitted By: LeeAnna

CNC stands for Computer numerical control. Just about every business that operates a manufacturing machine will usually have a cnc programming service operating it. The basic function of a cnc programming service has a cnc machine running it. The cnc machine is an automatic, precise, and consistent motion control mechanism. In the past, most automated machines needed someone to stand by the machine to make sure it was lined up properly and made sure that it repeated a certain function that is required from the machine. For a better explanation, I'm going to use the example the website I researched for this information used to make things a bit more clear. A drill press is used to machine holes, this is a repetitive motion, however, a person must stand over the machine to line up the drill with the holes and make sure the drill stays lined up. A person is required to do something every step of the way. However, a person can only do so much, and as production grows so will the amount of “holes” so to speak, and the operator will eventually find it hard to keep up. In order to create more production, a cnc programming service and set up can be added. The cnc machine can do everything that an operator would be required to do. Once the machine is setup and running, it can take the place of the operators, the cnc machine is so easy to run, the operators tend to get bored during lengthy productions.

The cnc machine or course can do much more complicated operations that require much higher skill levels. A cnc programming service can improve automation so much that most of the time operator intervention can be reduced or all together eliminated to do other things. The second benefit is that cnc programming services and technology is consistent and accurate and once the program is verified, the machine will run efficiently and consistent, no matter how many work pieces need to be produced. A third benefit offered by most forms of CNC machine tools is flexibility. Since these machines are run from programs, running a different work piece is almost as easy as loading a different program. Once a program has been verified and executed for one production run, it can be easily recalled the next time the work piece is to be run. This leads to yet another benefit, a fast change over. Since these machines are very easy to setup and run, and since programs can be easily loaded, they allow very short setup time. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. If you need more information about cnc programming services there is a lot of information about it online.

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Article Source: iSnare.com

CAD Design Process - CNC Process

Submitted By: Ivon Irons

AD Design Process

When designing something complex in CAD you will find there is a bit of a process. First you design parts. Then you build the parts into Sub-Assemblies. Next you build sub-assemblies into Groups. Then you build the groups into the machine. It is a logical pyramid process. You can also think of it like a file structure inside of a computer.

Designing Parts

Parts are your building blocks. Without this level, nothing could be produced. The part level breaks the entire “thing” down to its simplest form. You also manufacture at the part level. You make parts, and then assemble them into other things. Parts are generally made out of raw materials.

Think of a differential on the rear axel of a car. The differential is made up of gears and a housing. Each of these are parts of the differential and the differential is the assembly of these parts.

Designing Sub Assemblies

Sub Assemblies are the next level up and I am guessing you are getting the idea. You first design parts, then put them together into sub assemblies. In the car example above the differential is a sub assembly in the axel “Group” of the car. Sub Assemblies are put together to form groups.

Designing Groups

Moving up the design chain, groups are usually things you can identify with. It could be a door, engine, transmission, or cooling package on a car. Above we used the example of an Axle as a Group. Groups are put together into machines. Our example is a car, which is at the machine level.

Designing the Machine

Finally, the top level of all your designing, the machine. The machine could be built for the end user or be sold to another manufacturer. That manufacturer could use your “machine” as a sub assembly or group. You can see all this is just a matter of viewpoint. You can consider just about anything a sub assembly, group or final machine. It is all just semantics and what you are using the item for.

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Article Source: iSnare.com

Casting

Lost Foam Metal Casting, Casting, And Metal Casting Information

Submitted By: Kent Klein

Lost Foam Casting is a relatively new casting process compared to other metal casting procedures that date far back into antiquity. The first patent for Lost Foam Casting was made in 1958 but it was not until 1964 that what we know commonly as Lost Foam Casting was introduced.

Lost Foam Casting is a form of Investment Casting much like Lost Wax Casting. The key material of Lost Foam Casting is of course foam which is not used in other metal casting methods. The use of foam has many benefits to the artisan like ease of use and shaping and the relative inexpensive cost of the material. Each casting is going to be one of a kind since the original casting of foam is lost during the process.

The foam original will be replaced by the molten metal unlike the Lost Wax Casting where a wax mold is made of the original and then coated with a ceramic shell in preparation for the molten metal. Luckily, most foam is pretty inexpensive so the loss of the original shouldn't pose a significant financial loss, just an annoying creative loss.

Foam is easily shaped by hand held tools but even still some practice may be needed to prefect the sculpting of the material. You will need to place a sprue into the foam which will allow the molten alloy to spread into the foam and adopt the shape of the item. Packing the foam and sprue in sand is a good way to insure that the mold will retain its shape through the pouring process. The metal will replace the foam by vaporizing it, and it is really quite a sight to behold.

Though there are many who prefer to adopt the procedures used in Lost Wax Casting for the Foam casting. After spruing the foam original you are going to dip it into a solution to create a shell and then pour the metal. The goal of this is to create a cleaner surface.

Whichever method you choose is really up to you. Many use Lost Foam Casting a quick and easy way to create something when visual appearance isn't all that important. Many refer to Lost Foam as the "quick and dirty method".

As for the type of foam to use you are going to want to steer clear of anything that will give off toxic fumes when heated. Urethane foam is toxic. The popular foams to use are the polystyrene kind which is used to pack electronics and the polystyrene foam used for insulation. These foams can be found at many home improvement stores and even a few all purpose retail stores.

Lost Foam Casting is kind of like alchemy, transforming something inexpensive into something invaluable. Whenever you cast, make sure to take all proper safety precautions and wear safety gear. Always wear a long sleeve shirt, jeans, and the proper shoes. Don't forget eye and face wear and of course gloves. Never forget that you are dealing with material that can very easily harm and disfigure or worse if not handled properly.

Many first time casters begin with Lost Foam Casting since it doesn't involve mold making but if you are experienced and never attempted this method you will still want to be careful.

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Article Source: iSnare.com

Metal Casting Tools And Definitions Of Metal Casting Tools

Submitted By: Kent Klein

There are various types of casting tools. Provided below are details of some of the casting tools.

Esmarch plaster scissors: These are German stainless steel cast scissors of high quality. The entire length is 20 centimeters or 8 inches. There is a 6 centimeters slanted blade for safety of the patient. The handle for leverage is of 15 centimeters. This is perfect to cut the inner layers of synthetic cast materials or plaster.

Lister bandage scissors: These are stainless steel bandage scissors of high quality. The size of the blade is 5.5 centimeters. It resists rust and corrosion. This scissors are perfect to remove QuickCast splints and casts.

Cast scissors for serial finger casts: These are manufactured from German stainless steel of highest quality. The total length is 9 centimeters. There is a 1.3 centimeters slant design on the cutting surface. During cast removal, there is good patient safety and the scissors offer excellent force.

Cast spreader: This has a stainless steel construction. There is a spring loaded handle to facilitate use.

Cast breaker: The length of the cast breaker is seven inches. This is an O.R. quality German instrument. This is used for lightweight cast breaking and trimming. This has deep serrated tips and is free of latex. The cast breaker is available in sizes of 9.5 inches also.

Plaster and Utility shears: The length of this instrument is 8 inches. This is a German instrument of O.R. quality. There is a spring loaded handle design that decreases the hand fatigue. This is very efficient in case of cotton or cloth wadding. It is free of latex.

Wire suture scissors: This is a stainless steel scissors of high quality. This is a perfect device to remove finger serial casts and to make tight corner cuts.

Fiskars all purpose snips: This instrument has a positive safety latch, a stainless steel spring and a comfort grip. The design is such that there is maximum power and handling ease. The stainless steel blades of high quality are used to cut a wide range of materials. Low temperature thermoplastics can be cut at room temperature by this device.

Aviation snips: These snips are of industry quality. Non-heated splinting material can be cut with efficiency. It can be used to cut straight lines as well as wide curves. The handles are coated with plastic to increase the comfort. This device can be used in the left hand as well as right hand.

Softouch spring action scissors: Those who have weak hands can also operate these by employing half the effort. There is a gray cushion grip. This is used to provide relief to the finger and thumb discomfort. It also absorbs squeezing pressure. The handle can be easily gripped and used in the left hand or right hand. There is a gentle spring action to open blades at the end of each cut. This offers relief to the hand and joints. There is a large slide lock for single handed operation. This also maintains the blades closed for portability and safe storage. It is free of latex.

Cast stand: The height can be adjusted. This comprises of a drip bucket. While the limb is being casted, it provides support to the arm or leg of the patient.

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Article Source: iSnare.com

Metal Casting Information And Basic Metal Casting Information

Submitted By: Kent Klein

Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. The ejection or breaking out of the casting then takes place to get the process completed. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Complex shapes are normally made by casting, as other methods are not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting.

‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.

Continuous casting: Continuous casting can be defined as a refined process of casting for high-volume, continuous production of ‘metal sections’ with constant cross-section. The pouring of molten metal into a water-cooled, open-ended copper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formed above the ‘still-liquid’ center. Continuous casting is widely accepted due to its cost-effectiveness. The metals continuously cast are aluminum, copper, and steel.

Centifugal casting: Centrifugal casting is independent of both-pressure and gravity. This is because its own ‘force feed’ is created by the way of using a ‘temporary sand mold’ in ‘spinning chamber’ at 900 N. Lead time is variant with respect to application. True- and semi-centrifugal processing allow 30 to 50 pieces/hr. The batch processing has an upper limit of around 9000 Kg (practically). This method used to be applied for ‘Casting of Railway Wheels’. It was developed by the company called ‘Krupp’. It had a German origin. Jewelry is normally cast by this method.

Die-casting: Die casting can be defined as a process of ‘forcing molten metal’ into cavities of mold under high pressure. These castings comprise of nonferrous metals, especially-alloys of aluminum, copper, and zinc. It is even possible to make die castings of metal. The method of die casting is used where finer parts are needed.

‘Permanent Mold Casting’: This casting is made up of non-ferrous metals. It requires some time to set up (some weeks), after which the production rate of about 5 to 50 pieces/hour-mold is achieved. The coating of ‘acetylene soot’ is applied to steel cavities. This helps in removing the work piece easily and promoting longer life (of tools). Permanent molds possess a limited life span. For worn molds, replacement or refinishing is required.

Expendable mold casting: ‘Expendable Mold casting’ can be referred to as a standard classification inclusive of the following:

Sand casting: It is amongst the simplest and most popular casting types used since ages. It involves very small size operations. The bonding of sand takes place by use of clays (as in ‘green sand’) or ‘polymerized oils’, or ‘chemical binders’. Recycling is easily possible.

Plaster casting (for metals): There is no difference between plaster casting and sand casting, except the fact that plaster is used in place of sand. Similarly, there are also plastic and concrete castings.

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Article Source: iSnare.com

Spin Casting, Sand Casting, And Other Metal Casting Processes

Submitted By: Kent Klein

There are various casting processes being implemented now days. The oldest amongst them is sand casting. Spin casting is also widely used. They can be described as follows:

Sand Casting: Sand casting involves formation of mold from a mixture of sand and to pour a casting liquid, most probably, a molten metal into mold. The metal is then allowed to solidify and the removal of mold, takes place. Sand molding consists of two types: green sand method and air set method. The first one consists of mixture of clay, moisture, silica, and many other additives. The second one consists of mixture of dry sand and other materials, not moist clay. They are mixed with the help of a quick curing adhesive. The collective use of these materials is called ‘air set’.

At times, there is temporary plug placed to pour the fluid which is to be molded. Air-set molds usually form molds consisting of two parts-the bottom and the top. The mixture of sand gets tamped down after its addition. It does not generate any by-product. After the solidification and cooling of metal, the mold gets usually destroyed. This is because its removal involves a lot of breaking and cracking. The casting accuracy depends a great deal on the sand and the process of molding used. Castings composed of green sand result into formation of rough texture on casting surface, and this characteristic makes them easily recognizable. Air-set molds produce smoother castings.

Many a times, the casting process results in losing of components of sand mixture. It is possible to reuse green sand by the way of adjusting the composition to get the lost additives and moisture replenished. The entire pattern itself is eligible to be reused for producing novel sand molds. The method of reuse can be continued for an indefinite period. In 1950, casting process got automated partially. They have been in great demand for developing production lines since then.

Spin Casting: Spin Casting is better known as Centrifugal Rubber Mold Casting (CRMC). It implies utilization of centrifugal force for producing castings out of rubber mold. As a customary practice, a mold having shape of a disc gets spun through its ‘central axis’ at a pre-decided speed. The material used for casting is usually thermoset plastic in the liquid form or a molten metal. It gets poured into the mold through the opening at its centre. Corresponding to the solidification of metal, or the setting of thermoset plastic, the spinning of the filled mold takes place.

Normally, organic rubber or vulcanized silicone is used as a mold-making substrate in spin casting. Vulcanization takes place in the middle of process of mold-making. After the successful completion of vulcanization process, venting and gating must be undergone by the mold. This implies carving of channels for ensuring proper material flow and air during the course of casting. A scalpel or knife is used to carry out the above two processes. The mold complexity is directly proportional to the time required in implementation of venting and gating.