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Warm Forging Process

Warm forging is performed with the workpiece heated to a range that is generally above the work hardening temperature and below the temperature at which scale forms. The process fills the niche between the closer tolerance, but sometimes expensive cold forging process and the somewhat lower precision hot forging process. It is being used to produce close tolerance components in steel alloys that were not feasible or impossible by cold forging. It is also being used to produce components very […]

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Cold Forging Process

Cold Forging Process Cold forging is one of the most widely used chipless forming processes, often requiring no machining other than drilling. The commonly accepted definition is the forming or forging of a bulk material at room temperature with no heating of the initial slug or inter-stages. The term “no heating” does not include in-process annealing, which may be performed at intermediate stages to relieve the effects of work hardening. The process produces greater dimensional accuracy than hot forming, and […]

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The process of injection molding explained

Injection molding is a manufacturing process used to produce single parts and products using various materials, most commonly thermosetting and thermoplastic polymers. Today, injection molding is the most popular method of manufacturing parts and is used to produce a variety of everyday plastic products, including packaging, toys, telephones, bottle lids, chairs and many more. Injection molding is also used to manufacture complex, small metal parts, known as Metal Injection Molding (MIM). But just how does injection molding work? The machine An injection […]

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MIM – Advanced technology that brings the future of metalworking to the present

Representing one of the advanced metal processing techniques, MIM (Metal Injection Molding) was created by fusing traditional plastic injection molding technology with powder metallurgy. Injection molding using metal dies makes it easy to manufacture otherwise hard to machine parts, including micro, precision, intricately shaped, and 3D parts. MIM is also superbly suited for mass production, as demonstrated by our ability to manufacture at rates ranging from 5,000 to 1 million pieces per month. MIM works best for parts that weigh […]

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3D Printing is Changing Manufacturing of Complex Composite Parts

3D printing is an additive manufacturing process that works best for functional prototypes, complex designs, reducing multipart assemblies, and end-use applications. 3D printing technology is rapidly changing how manufacturers are creating concept models and end-use parts. One of the fastest growing applications is utilizing 3D printing technology for the tooling of complex and low volume composite parts. Boeing and other companies in the aerospace and automotive industries are finding that using composite materials instead of metal, greatly reduces the weight and […]

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Top-10 Injection Molding Defects and How to Fix Them

Making injection molded prototypes is both an art and a science. High levels of technical expertise and attention to detail are required to prevent small mistakes from costing companies big money when it comes to mass-production of novel parts. Preventing such a circumstance is all about highly competent design. This article discusses some of the molding defects that can occur in a part during injection molding, and ways to fix and avoid them. Design shortcomings we will discuss include: Flow […]

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Eyeglass Frame Material

Eyeglass frames are made out of many different composite materials and formulas, but the basic groupings are metal and plastic. In plastics, zyl is the most common although lower quality plastics are used in the cheaper frames. Nylon is often used in sport sunglasses due to its impact resistance and flexibility. Among the metals, monel is most common, followed by titanium, stainless steel, nickel silver, alpaca, and aluminum. Zyl Zyl is a short name for the material cellulose acetate, which […]

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Titanium

Titanium is 30% stronger than steel, but is nearly 50% lighter. Titanium is 60% heavier than aluminum, but twice as strong. Titanium has excellent strength retention to 1,000 degrees Fahrenheit. Titanium is alloyed with aluminum, manganese, iron, molybdenum and other metals to increase strength, to withstand high temperatures, and to lighten the resultant alloy. Titanium’s high corrosion resistance is also a valuable characteristic; as when exposed to the atmosphere, titanium forms a tight, tenacious oxide film that resists many corrosive […]

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How to Stop Flash in Injection Molding?

Troubleshooting flash is complicated, and often there is a lot of tail-chasing on the shop floor in trying to get a solution. This approach should lead you to the solution via a data-driven procedure. Testing the parting line, using pressure-indicating paper: The image on the left is flash-free. The part on the right side is flashed; note the location of flash where the paper is mostly white at the top and bottom. The white color indicates the parting-line touch force […]

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Progressive Die Stamping

Progressive die presses stamp metal using a forming method that can encompass bending, cutting, punching and several other ways of modifying coil sheet steel. The automatic feeding system pushes a strip of metal (as it unrolls from a coil) through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made. The final station is a cutoff operation, which separates the finished part from the carrying web. The carrying […]

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