Plant Support Machinery
As the name suggest, the plant support machinery are equipment that support the more specialized operation in an industrial plant. They are not the main machines, but plant support machinery play a vital part that allow operations to be completed. Whether to lift finish products from the assembly line to storage, clean-up the working area or create cartons or crates where the finished product will be stored, there is always a plant support machine that does the work.
Surprisingly, these machines are quite familiar to you and me. Examples of which are the following:
The air compressor is a machine that increases the pressure of air by increasing its density and delivering the fluid against the connected system resistance on the discharge side.
The boiler is a machine that is used to generate steam. It is made of up two major parts namely the furnace and the boiler proper. The furnace provides the heat, while the boiler proper converts the water into steam through the heat generated by the furnace.
The air spray gun is used in spray painting or coloring a surface using a spraying a device instead of the usual paint brush. Air spray gun utilizes compressed gas to discharge the pain particles from the sprayer onto the surface being painted. The basic parts of the air spray gun are the nozzle, paint basin and air compressor.
The air spray gun is the offspring of the paint brush. The technology for air spray gun came about the surfaces needing pain have become larger and the time required to finish the activity has become shorter.
The industrial floor cleaning machines are advanced floor cleaning equipment that are easy-to-use and easy-to-maintain. These are for tough industrial cleaning needs. The sweepers, vacuum cleaners, scrubbers and pressure washers fall under this category.
A forklift is a powered industrial truck used to lift and transport materials and is an indispensable piece of equipment in manufacturing and warehousing operations.
A crane is an equipment used to lift or lower objects that are beyond lifting by use of sheer manpower, usually towards a horizontal direction. It is a combination of several simple machines such as the level and the wheel. The crane is commonly used in industries related to freight, construction and manufacturing of heavy equipment.
These are just few of plant support machinery around you. The good news is, if you are tight on the budget, there are second hand plant support machinery that are available to meet your needs.
What are Vertical Machining Centers (VMCs)?
Machining centers, also known as CNC milling machines, are computer controlled mills that cut materials into a desired geometry or shape. The milling machine has two kinds of machining centers, the horizontal and the vertical machining centers. The form of the machine refers to the orientation of the spindle.
The CNC milling machines are not like the drill press where it holds a workpiece in place while the drill cuts through the material. In milling machines, the cutter is not the only one that rotates but the workpiece is also moved against the cutter that cuts both the flanks and its tip.
Most CNC milling machines are vertical mills whose spindles move across the length of the Z-axis. The structure of vertical machining centers or VMCs gives more freedom for it to be effectively used in engraving, diesinking, and 2.5D surfaces like a raised carving. Moreover, when this is combined with a ball nose cutter or conical tools, the milling precision is drastically improved while its speed is maintained. This then results into a more cost-efficient process.
There are quite a number of manufacturers today who specialize in providing the best VMCs in the market. Some of these providers are Haas, Okuma, Makino, Toyoda, Fadal, Kitamura, Matsuura, and Quickmill among others.
Given the continuous evolution and the need for more efficiency in the industrial sector, manufacturers of vertical machining centers are incessantly looking for ways to cut down on costs and reduce leadtimes. It is therefore imperative that you are armed with the knowledge of what VMC would work best to meet your needs.
It is no longer just comparing the spindle horsepower torque nor the purchase price. Choosing the best VMC for you means you need to examine the different aspects of the machine’s performance such as its capacity to make highly accurate cuts and the quality of its surface finish. Other important aspects to look into are the machine’s stability and construction, spindle design and the thermal stability.
Due to the declining cost of computers as well as the rise of the availability of open source CNC software, the price of CNC machines has also plunged. Therefore, it is best to do your research first on the best vertical machining centers prior to purchasing one. The savings you will get for more efficient operations plus the quality of the finished products would more than likely compensate for the difference in the purchase price of the VMC.
Press Breaks and Shears: Understanding the Uses and Types of Press Breaks and Shears
Press breaks and shears are examples of fabricating tools.
Fabrication tools, in industrial terms, are used for cutting, shaping and assembling components of materials such as metal. Fabrication tools could be a basic hand tool to the most complex machines used by large industrial firms. Nevertheless, each of these tools falls on the same basic concept of fabricating.
A press brake is used for bending sheet and plate material. Mechanical, pneumatic, hydraulic and servo-electric are the various types of brakes.
A mechanical press is used to apply an intense force to form, shape, or cut materials. It is also used for shearing or forming sheet metal. It is made out of structural frame, lower stationary base, and an upper ram that applies the force.
Pneumatic presses make use of air pressure to create a tonnage on the ram. Pneumatic and servo-electric machines are commonly used in lower tonnage applications. A hydraulic press uses one or more cylinders and fluid at an elevated pressure, to move a cylinder piston and produce the force. Similar to hydraulic press, pneumatic presses utilize pressurized air versus fluid. A back gauge or otherwise known as a backage is a device that is attached to a press brake. It is used to correctly position a piece of metal in order for the brake to properly place the bend.
Shears are used to shear sheet metal. By definition, shearing is to cut metal without burning or melting it. Sheet metals are generally the most sheared materials.
There are different types of shears. A bench shear is a bench mounted shear with a compound means of amplifying the mechanical advantage. In addition to that, it is used for cutting rough shapes out of medium sized pieces of sheet metal. A power shear is an electrically or pneumatically powered hand tool designed to blank huge sheets of metal. They are designed to cut straight lines as well as large radius curves. A throatless shear is a cutting tool utilized to make complex straight and curved cuts in sheet metal.
It is essential to know these various kinds of press breaks and shears. Each type serves a different purpose and knowing what specific tool you need is a definite advantage in searching for the best deal. It is quite easy to purchase press breaks and shears as there are a number of vendors and distributors of fabrication tools wherever you may be. The most accessible and convenient place to shop, however, is the World Wide Web.
There are numerous companies over the web that sells fabrication tools and even used machineries. Make sure though to choose a seller that offers you with all the necessary information about their products. It is vital that the seller works hand in hand with you in choosing the machine until the moment you purchase it.
Press breaks and shears are helpful tools for industrial works. Purchasing such fabrication tools should be given high regard since the quality of work and result will also depend on the quality of the tool you are using.
Turret Punches and The Types of CNC Turret Punches
Punch presses are used to cut holes in a material.
Generally, punch presses are massive machines with either a “C” kind of frame or a bridge type of frame. Every punch press machine has a table with rollers that permits the sheet metal to cross with low friction.
A punch press is identified by specifications like frame type, size of working area, single or multiple station, force rating, the kind of tool shop and its capacity, utmost weight of the material, safety features, etc. It could be computer numerically controlled (CNC) such as the CNC turret punch press.
There are various shapes that can be made in sheet material by repeatedly punching a succession of basic shapes using the CNC turret punching. The shapes are picked from a revolving turret which is under CNC control. For moderate to long runs, CNC turret punching is a practical way for cutting sheet metals. CNC turret punching could also create 2D shapes and that includes cutouts.
You will find that there are different types of CNC turret punches. CNC Hydraulic Turret Punch Press is one of these. A hydraulic punch press is either valve or feedback controlled. Valve controlled machines generally allow one stroke operations. This permits the ram to move up and down when controlled.
Another type is the CNC Mechanical Turret Punch Press. Mechanical punch presses could be further categorized into two types. Older presses are full revolution presses that need a full spin of the crankshaft to be put into a halt. This happens for the reason that the breaking mechanism relies on a set of raised keys to descent on into corresponding slots to stop the ram. Current presses, on the other hand, usually only require part revolution. Upon applying air, a band -type brake extends and permits the crankshaft to rotate.
Turret punch presses play a huge role in today’s modern society. It is a vital piece of equipment that an industrialized place will surely need.
The Types and Best Uses of Grinders
Grinding machine or a grinder is a tool that makes fine touches out of metals and other materials through its abrasive wheel which is used as the cutting tool. Its abrasive wheel is rotating so that it would alter the shape and dimensions of a solid object which then produces light finishes.
Grinding is a finishing process used to erode solid materials and enhance surface finish. Also, this process is used to tighten the tolerance on plane and cylindrical surfaces through the removal of a small quantity of material.
Grinders are composed of a power driven grinding wheel which rotates at a desired speed. It is actuated through the wheels diameter and manufacturers rating. The grinding head could be commanded to travel over a fixed work-piece. Grinding machinery detaches material from the work-piece through abrasion, which can produce ample amounts of heat. Its user then does cooling on the work-piece subsequently, to avoid overheating and exceeding the material’s tolerance.
There are various reasons for using grinders. First, the object could be too rocklike to be machined economically. Another reason is that tolerances desired inhibit machining. Lastly, machining could take away too much material.
There are different types of grinders. Each type serves a specific purpose and have their particular uses.
Among the types of grinders are the angle grinders. This kind of grinder is best for finishing, patterning, deburring and cutting. Backstand grinders are best for casual grinding or finishing. The belt grinders on the other hand could be used for the removal of micro burrs, for polishing and finishing surface roughness. It could also be used for edge breaking, dimensioning and eradicating tool marks. Bench grinders are used for roughly shape metal before welding.
Another type of grinder, cylindrical grinder, is used to shape the outside of a material. Additionally, surface grinder is used to produce a smooth finish on flat surfaces. A jig grinder is a tool used for grinding complicated shapes and holes where utmost degrees of precision and finish are desired. Another grinding machine is the rotary grinding machine which has multiple grinding wheels where the object is rotated and fed past the wheel to create a cylinder.
Grinders are an important machinery tool. It is certainly very useful in the industry. There are different uses for grinding machines and each grinder is essential towards carrying out industrial work.
Difference between Vertical Machine Centers and Horizontal Machine Centers
Machining Centers, also known as milling machine, are computer-controlled mills used in the industrial setting to cut materials to a shape or geometry. It is also used for slot and keyway cutting, planing, drilling, diesinking, rebating and routing.
There are two machining center forms, the horizontal and vertical. This refers to the main spindles orientation. Both the horizontal and vertical machining centers come in small, bench-mounted devices to a room-sized machine.
Horizontal machining centers have x – y table with cutter mounted on a horizontal arbor across the table. Most horizontal machining centers highlight a =15/-15 degree rotary table allowing one to mill at shallow angles. Horizontal machining centers are often used to mill grooves and slots. It may also be used to shape flat surfaces.
Vertical machining centers have its spindle axis vertically oriented. Its milling cutters are held in the spindle and it rotates on its axis. Generally, the spindle could be extended to allow plunge cuts and drilling, although the table could also be lowered or raised. The vertical machining centers have two subcategories. These categories are the bedmill and the turret mill.
Although they may be similar since both are machining centers, vertical and horizontal machining centers serve different purposes. Horizontal machining centers were first to appear to put milling tables under lathe-like headstocks. However, through the desire to change the angle of the horizontal machining centers, accessories such as add-on heads were created to convert the horizontal to vertical machining centers.
Horizontal machining centers work best with heavy work piece that needs machining on multiple sides. Diesinking on the other hand is best with vertical machining centers. With the technology that we now have, switching from vertical to horizontal machining centers or vice versa is now possible and you can easily do so depending on your need.
The Best Super Mini Mills
A Super Mini Mill is a proven stipulation characterized by low cutting forces and high metal removal. It is a small CNC machine used in the milling industry that combines high spindle speeds with increased feed rates. This results in a high chip-forming rate and lower milling forces, producing an improved surface quality and closer tolerances.
In high speed milling, the electronics can make all the difference. The right super mini mill coupled with other elements of the control system will let it mill faster with a higher speed rate comparing with the normal milling machine.
Haas Automation’s Super Mini Mill has higher speeds and feeds, a 10,000 rev/min ISO 40-taper spindle, an 11,2kW vector drive system and a high-speed tool changer. It is the ideal machine for the type of drilling and tapping required by the electronics industry, or for high-speed contouring of graphite electrodes or small molds.
The Super Mini Mill runs on three-phase power, and features a 15-hp vector drive spindle that accepts standard 40-taper tooling. With cutting feed rates of up to 833 ipm, 1200-ipm rapids and 2.5-second tool changes, cycle times on the Super Mini Mill are kept to a minimum.
When Haas introduced the Mini Mill in 2000, it quickly became one of the best selling machines in the company’s history. Its combination of small footprint, full CNC capabilities and sub $3000 price were unheard of in the industry. The Super Mini Mill added even more capabilities, while maintaining the same compact footprint and affordability.
Now, Haas Automation has launched the Super Mini Mill 2 which is based on the Mini Mill 2. The Super Mini Mill 2 takes up little shop floor space yet provides a generous work envelope of 508 x 405 x 356 mm (xyz). It comes standard with a 10,000-rpm spindle, 30.5m/min rapids, 1 MB of program memory, rigid tapping and a high-speed tool changer. It also offers you an option to either go for a 20-pocket carousel tool changer or a 24+1 tool side-mount depending on your shop’s requirement.
Although the Super Mini Mill 2 has the same travel dimensions as that of the Sper Mini Mill, it boasts of higher speeds, feeds and more options. The spindle is capable of 10,000 rpm with an optional 15,000 rpm spindle, along with a 15-hp vector drive system, high-speed tool changer and 1,200-ipm rapids. Moreover, a coolant system and rigid tapping are likewise part of the package.
Like all of Haas CNC machines, the Super Mini Mill 2 features the same reliability and quality output especially when it comes to handling small-parts manufacturing. It is ideal for finishing work and cutting aluminum as well as providing enough low-end torque to cut steel.
The Difference between Mills and Grinders
There are a number of differences between millers and grinders. Millers could do more operations than grinders. Moreover, millers could accomplish extensive works than the grinders which are limited to a few operations. Millers could do harder and massive workpiece than grinders. Nevertheless, grinders and millers are two essential machining tools used in the industry with their own specific and vital roles and uses. Now, let’s delve deeper into the works of both of these machining tools.
Grinders are a kind of machining that use an abrasive wheel as the cutting tool. The grains of abrasive cut a tiny chip from the workpiece through shear deformation. Grinders have a power-operated grinding wheel which rotate at the desired speed and contain a bed that accommodates a fixture to hold the workpiece. Through abrasion, grinders can take away the material from the workpiece. Subsequently it produces heat and therefore a coolant is used afterwards in order for the material to avoid from overheating. There are various types of grinders. Belt grinders are best for finishing and deburring. Bench grinders are used for shaping tools which need repair. Gear grinders are usually used for the final machining process when producing high precision equipment.
On the other hand, millers are used on machining solid materials. Horizontal and vertical are the two forms of millers. Millers put in motion the workpiece against a rotating cutter which cuts on its sides and tip. Millers can be manually operated or controlled through a computer numerical control which is otherwise known as CNC. Moreover, millers could do a wide array of operations including the most complex and complicated ones such as planing, slot and keyway cutting, diesinking, rebating, and routing among others.
Millers are classified according to various criteria: control, spindle axis rotation, purpose, size and power source.
Vertical and horizontal millers have a number of differences. Vertical mills have vertically oriented spindle axis. The milling cutters are placed in the spindle and spins on its axis. The bedmill and the turret mill are the two subcategories of vertical mills. Turret mills are smaller than bedmills but considered more flexible and functional. The turret mill operates with its spindle staying in place as the table moves parallel to and perpendicular to the axis of the spindle. Alternatively, the bedmill functions differently. Instead of the spindle remaining stationary, the spindle moves parallel to its axis while the table only moves perpendicularly to the spindle’s axis.
Horizontal mills on the other hand have cutters which are augmented on a horizontal shaft across the table. Most horizontal mills can mill at shallow angles because of its +15/-15 degree rotary table. Because the arbor provides good support to the cutters, the horizontal mills can make heavy cuts that make material removal rates much faster. What’s more, several cutters can be put together on the arbor to create more complex shapes. Likewise, there are specialty cutters that can mill according to any desired section such as grooves and radii. These specialty cutters are quite expensive though. It can also be noted that the horizontal mill can cut gears more easily as compared to vertical mills.
So that pretty much sums up and distinguishes what a grinder and a miller are. Both of these tools are considered vital and essential in the machining industry. Without it, cutting and forming workpieces would surely take ages to achieve.
Presses and Pumps and How to Properly Maintain Them
Presses and pumps are both important machines in the industry. These are of different kinds though but are designed to continually aid us human on carrying out our mechanical and industrial works.
A machine press or press is a machine tool that manipulates the shape of a work piece. There are various types of presses. Hydraulic press is a type of press machine that uses a hydraulic mechanism for utilizing a massive lifting. An arbor press, on the other hand, is used to do smaller machine works such as skating, riveting, installing, etc. A forging press reshapes the work piece into a three dimensional object including its internal structure. Another type is the press brake which bends sheet metal into shape.
Pumps are a device used to move fluids or gases. There are numerous kinds of pumps. A positive displacement pump is a type of pump that causes a fluid to move by trapping a fixed amount of it, subsequently displacing that trapped volume into the discharge pipe. Moreover, a hydraulic ram is a water pump that serves as a hydraulic transformer that absorbs water at one “hydraulic head” and flow-rate, and outputs water at a higher hydraulic-head and lower flow-rate. In addition to that, another type is the gravity pump which uses downhill flow to take in water from far-underground aquifers in high areas to distribute to consumers at lower sections.
Proper maintenance of presses and pumps is necessary and essential for them to continually help us with our various industrial works. It is moreover vital to keep these machines in good condition to increase its longevity. Purchasing new ones require time and effort not to mention costly. Thus, proper maintenance is the crucial to altogether avoid buying a new machine. So how do you maintain presses and pumps and keep in them in good working condition?
Basically, regular checking is the initial step towards proper maintenance. This is important to assess if there are any defects or there is a need for repair. You’ll never know when a machine would cause you a downturn hence regular maintenance checking is the key to avoid worse damages in the future.
Likewise, efficiency of these machines should be a top priority. Lubrication of the gears especially of presses is important. You could use graphite or paste wax in lubricating the gears. Presses could also be upgraded for smoother and more efficient operation. This is possible through the replacement and installation of the electrical controls of your press machine with a completely new control package which is specifically designed for your press’ application.
On the other hand, the major steps towards maintaining your pump’s efficiency are: pumps should be correctly sized, well-lubricated, and used and operated with utmost care. One must also be observant of unusual trends in its operation and act on these immediately if spotted.
Like any other machine, presses and pumps, do heavy-duty works and must be in tip-top shape to efficiently operate and deliver quality outputs. For these machines to continually operate effectively, it is of great importance to religiously pay close attention to its proper maintenance and safekeeping.
Practical Considerations in Buying Second Hand Metal Cutting Tools
In today’s financially challenging times, we are now, more than ever, conscious of the often used phrase “value for money” in making major purchases. Whether for business or personal use, we want to make sure that we buy items that are at the least possible price, and thus, we often resort to buying second hand metal cutting tools.
Metal cutting tools are machines that are used to cut, bore holes on, trim and other related activities on metals, diamonds, steel and other extremely hard substances. Examples of these tools are drills, mills, saws, dies, reamers, taps and broaches.
To ensure that you get the best deals when buying used metal cutting tools, you might want to check out the following:
1. Guarantee and Return Policy – buy only from a retailer that offers guarantee or allows return of unsatisfactory goods. Retailers who offer guarantee for their goods and has a return policy are most likely confident of the working condition of their products. The Trading Standards Institute mandates that companies that are trading second hand electrical goods are liable for the injuries or damages resulting from the use of their products that have not met safety requirements.
2. Price – Definitely, second hands are cheaper than brand new ones. Generally, used tools have half the price of brand new ones – including metal cutting machines that retailer claims to be used just once. But how do you know that a certain price tag is already cheap? You should make a canvass first and compare the prices from different retailers.
3. Product Reviews – If you are buying online, try to check out online reviews of the products and the retailers. This extra precaution may take a little of your time, but it sure is worth it. Remember that you are also after quality. You wouldn’t want your machine to quit on you in the middle of cutting a heavy piece of metal. Some online retailers also provide noise reviews of their machines. Make sure you include this one in your checklist because if you will be cutting metals in the confines of your residence, you would not want to get complaints from your neighbors about your overly loud metal cutting tool.
4. Energy Efficiency – Many old models of machines and equipment take up a lot of power, which in the long run, defeats your purpose for buying second hand metal cutting machines.
5. Tool’s Efficiency – If you are buying drill presses, ensure that the equipment is capable of making precise holes on the metal. Make sure that it does not heat up unreasonably.
The secret to buying second hand machine cutting tools is having adequate information about the product that you are buying and from whom you are buying it from. This way, you get both value for money and the quality that you are aiming for.