Metal Machining Process

Metal Surface Treatment

Wire Erosion

Electro-plating

Wire Erosion (Wire Cutting) is the use of moving metal wire (molybdenum wire, copper wire or alloy wire) as the electrode wire, and the pulse electric spark discharge between the electrode wire and the workpiece generates high temperature to melt or vaporize the metal, forming a slit, thereby cutting out the processing of the part.

Wire cutting is mainly used to process various complicated and precise small components, such as punches, dies, convex and concave dies, fixed plates, unloading plates, etc., forming tools, templates, and metals for EDM processing. Electrodes, various micro-hole grooves, narrow slits, arbitrary curves, etc.

Electroplating process is a method of laying a layer of metal on a conductor using the principle of electrolysis. Electroplating refers to a surface processing method in which the base metal to be plated is used as the cathode in a salt solution containing pre-plated metal, and the cations of the pre-plated metal in the plating solution are deposited on the surface of the base metal through electrolysis to form a plating layer。The purpose of electroplating is to plate a metal coating on the substrate to change the surface properties or size of the substrate.

Electroplating can enhance the corrosion resistance of metals (corrosion-resistant metals are mostly used for coating metals), increase hardness, prevent abrasion, and improve conductivity, smoothness, heat resistance and surface aesthetics. A technology that uses the principle of an electrolytic cell to deposit a metal coating with good adhesion but with different properties from the base material on mechanical products.

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Grinding

Physical Vapor Deposition

The processing method of cutting off excess material on the workpiece surface with grinding wheel or other abrasive tools is called grinding. Grinding is one of the main methods of finishing parts, but sometimes it is also used for rough machining, such as cutting off materials with grinding wheel, or cutting off the pouring, riser and flash on the casting. The common grinding methods can achieve the accuracy of IT7~IT5, and the surface roughness Ra is 0.8~0.2 μ m。 Grinding can process surfaces of various shapes, such as outer circle, inner hole, spline shaft, thread, gear tooth profile, machine tool guide surface, special forming surface and outer cone surface.

The essence of grinding is also a kind of cutting, but it has the following remarkable characteristics compared with turning, drilling and milling:

1) Grinding is multi-edge and micro-blade tool.

2) High grinding accuracy and low roughness Ra.

3) High grinding speed and high cutting temperature. The circumferential speed of the grinding wheel can reach 2000~6000m/min, and the linear speed of the grinding wheel can reach 60~250m/s in high-speed grinding. Therefore, the cutting temperature is very high during grinding, and the instantaneous temperature of grinding pressure can reach 800~1000 ℃.

4) It can process materials with high hardness. For example, it can process hardened steel, hard alloy workpiece, gem, glass and other products.

5) The back component of grinding is larger than that of other cutting methods. Because during grinding, the contact area between the grinding tool and the workpiece in the cutting direction is relatively large.

6) The abrasive tool has self-sharpening property and can carry out continuous powerful cutting.

Physical Vacuum Deposition short for PVD, refers to a method of heating metal or non-metallic materials under high vacuum conditions to evaporate and condense on the surface of the plated part (metal, semiconductor or insulator) to form a thin film.

PVD applications:

1. Application in hard coating: cutting tools, molds, wear-resistant and corrosion-resistant parts, etc.

2. Application in protective coatings: blades of aircraft engines, automobile steel plates, heat sinks, etc.

3. Application in the field of optical film: antireflection film, high reflection film, cut-off filter, anti-counterfeiting film, etc.

4. Application in architectural glass: solar control film, low-e glass, anti-fog and anti-dew, self-cleaning glass, etc.

5. Applications in the field of solar energy utilization: solar collector tubes, solar cells, etc.

6. Application in integrated circuit manufacturing: thin film resistors, thin film capacitors, thin film temperature sensors, etc.

7. Applications in the field of information display: LCD screens, plasma screens, etc.

8. Applications in the field of information storage: magnetic information storage, magneto-optical information storage, etc.

9. Application in decorative accessories: coating for mobile phone cases, watch cases, spectacle frames, hardware, small accessories, etc.

10. Applications in the field of electronic products: LCD monitors, LCD TVs, MP4, car displays, mobile phone displays, digital cameras, and handheld computers, etc.

11. Applications in the field of touch screens: mobile phones, computers, MP4 and other digital product screens.

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Metal Casting

Painting

Metal casting is a process in which metal is smelted into a liquid that meets certain requirements and poured into a casting mold. After cooling, solidification, and cleaning, a casting with a predetermined shape, size and performance is obtained. Generally used for metal fittings or handicrafts that requires less precision.

Painting refers to a processing method in which paint is atomized by a spray gun and coated on the surface of an object. There are many types of compressed air spray paint, high pressure airless spray paint, and electrostatic spray paint. The spraying operation has high production efficiency and is suitable for manual operations and industrial automation production. It has a wide range of applications, mainly in the fields of hardware, plastics, furniture, military industry, and ships. It is the most common coating method used today; spraying operations require environmental requirements. There are dust-free workshops ranging from one million to one hundred, and the spraying equipment includes spray guns, spray booths, paint supply rooms, curing furnaces/drying furnaces, spraying workpiece conveying equipment, anti-fogging and waste water, waste gas treatment equipment, etc.

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Sheet Metal Fabricating

Electrophoresis

Sheet metal Fabricating is a comprehensive cold working process for metal sheets (usually below 6mm), including shearing, punching/cutting/compounding, folding, riveting, splicing, forming, etc. Generally used in the manufacture of various metal cases, protective shells, circuit board shields, etc.

Electro-coating (electro-coating) is a coating method in which particles such as pigments and resins suspended in the electrophoretic fluid are oriented to migrate and deposit on the surface of one of the electrodes by using an external electric field. The principle of electrophoretic coating was invented at the end of the 1930s, but the technology was developed and obtained industrial application after 1963. Electrophoretic coating is a special coating film forming method developed in the past 30 years. It has the characteristics of water-soluble, non-toxic, easy to automate control, etc., and is quickly widely used in industries such as automobiles, building materials, hardware, and home appliances.

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Laser Engraving

Powder Coating

Laser engraving is based on numerical control technology, and laser is the processing medium. The processing material melts and vaporizes physically under the laser irradiation to achieve the purpose of processing. Laser processing characteristics: no contact with the surface of the material, unaffected by mechanical movement, the surface will not be deformed, and generally do not need to be fixed. Not affected by the elasticity and flexibility of the material, it is convenient to process soft materials. With high processing precision and fast speed, it is widely used in advertising decoration, printing and packaging, leather clothing, model making, craft gifts and other fields.

Powder spraying: the powder coating is sprayed on the surface of the workpiece with powder spraying equipment (electrostatic spraying machine). Under the action of static electricity, the powder will be uniformly adsorbed on the surface of the workpiece to form a powder coating; the powder coating is subjected to high temperature Baking, leveling and curing, it becomes the final coating with different effects (different types of powder coating effects)

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Laser Beam Welding & Diffusion Bonding

Polishing

Diffusion welding refers to a solid-state welding method that pressurizes the workpiece at high temperature, but does not produce visible deformation and relative movement. The small unevenness of the welding surface produces microscopic plastic deformation to achieve close contact. In the subsequent heating and heat preservation, the atoms diffuse each other to form a welding method of metallurgical connection. This type of diffusion welding is usually called solid phase diffusion. It is characterized by high requirements on the surface quality to be welded, long welding time, and unstable joint quality. Diffusion welding is particularly suitable for joining new materials such as dissimilar metal materials, heat-resistant alloys, ceramics, intermetallic compounds, and composite materials, especially for materials that are difficult to weld by fusion welding. Diffusion welding has obvious advantages.

Laser welding technology belongs to fusion welding, which uses laser beam as energy source to make it impinge on the weldment joint to achieve the purpose of welding. It belongs to fusion welding, which uses a laser beam as the energy source to impinge on the weldment joint. 　The laser beam can be guided by a flat optical element (such as a mirror), and then a reflective focusing element or lens is used to project the beam on the weld. Laser welding is non-contact welding, and no pressure is required during the operation.

Polishing refers to the processing method that uses mechanical, chemical or electrochemical action to reduce the surface roughness of the workpiece to obtain a bright and flat surface. It refers to the finishing of the workpiece surface with polishing tools and abrasive particles or other polishing media. Polishing can not improve the dimensional accuracy or geometric shape accuracy of the workpiece, but aims to obtain a smooth surface or mirror gloss, and sometimes is also used to eliminate gloss.

Polishing can be divided into three categories according to different processing methods: physical polishing and chemical polishing.

Physical polishing usually uses polishing wheel as polishing tool. The polishing wheel is generally made of multi-layer canvas, felt or leather, and the two sides are clamped with metal circular plates. Its rim is coated with polishing agent which is uniformly mixed with micro-powder abrasive and grease.

Chemical polishing is to achieve bright and smooth metal surface through regular dissolution. In the process of chemical polishing, the passive oxide film and the oxide film are continuously formed on the surface of steel parts, and the former is stronger than the latter. Due to the micro-consistency of the surface of the part, the convex part of the surface has priority to dissolve, and the dissolution rate is greater than that of the concave part; Moreover, the dissolution of the film and the formation of the film are always carried out at the same time, but the rate is different. As a result, the surface roughness of the steel parts can be leveled, so as to obtain a smooth and bright surface. Polishing can fill surface pores, scratches and other surface defects, thus improving fatigue resistance and corrosion resistance.

Electrolytic polishing. Electrolytic polishing is to take the workpiece to be polished as the anode and the insoluble metal as the cathode. The two electrodes are immersed into the electrolytic bath at the same time, and the selective anodic dissolution is generated by direct current, so as to increase the surface brightness of the workpiece and achieve the mirror effect.

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Screen Printing

Color Filling

Screen printing is to stretch silk fabric, synthetic fiber fabric or metal mesh on the screen frame, and use the method of hand engraving paint film or photochemical plate making to make the screen printing plate. Modern screen printing technology uses photosensitive materials to make a screen printing plate (make the screen holes of the graphic part of the screen printing plate through holes, and the screen holes of the non-graphic part are blocked. Live) Oil paintings, prints, posters, business cards, bound covers, commodity packaging, commodity signs, printed and dyed textiles, glass and metal and other plane carriers.

Color Filling is also called painting or coloring. This process is an extremely important link in the whole label production. The current painting process is generally divided into manual painting and electrophoretic painting. However, due to some limitations of electrophoretic painting, manual painting is still the most widely used.

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Heat treatment

Brushing & Sand Blasting

Heat treatment refers to a metal thermal processing technology in which the material is in a solid state through heating, heat preservation and cooling to obtain the expected structure and performance. Metal heat treatment is one of the important processes in mechanical manufacturing. Compared with other processing processes, heat treatment generally does not change the shape and overall chemical composition of the workpiece, but by changing the internal microstructure of the workpiece, or changing the chemical composition of the surface of the workpiece, To give or improve the performance of the workpiece. Its characteristic is to improve the internal quality of the workpiece, which is generally not visible to the naked eye. In order to make the metal workpiece have the required mechanical properties, physical properties and chemical properties, in addition to the reasonable selection of materials and various forming processes, heat treatment processes are often indispensable. Steel is the most widely used material in the machinery industry. The microstructure of steel is complex and can be controlled by heat treatment. Therefore, the heat treatment of steel is the main content of metal heat treatment. In addition, aluminum, copper, magnesium, titanium, etc. and their alloys can also change their mechanical, physical and chemical properties through heat treatment to obtain different performance properties.

Brushing and sand blasting are commonly used for surface treatment of metal appearance parts.

Surface Brushing treatment is a surface treatment method that forms lines on the surface of the workpiece through grinding products to achieve decorative effects. As the surface Brushing treatment can reflect the texture of metal materials, it has been loved by more and more users and widely used.

Sand blasting is the process of cleaning and coarsening the substrate surface by using the impact of high-speed sand flow. The compressed air is used as the power to form a high-speed spray beam to spray the sprayed materials (copper ore, quartz sand, emery, iron sand, Hainan sand) onto the surface of the workpiece to be treated at high speed, which changes the appearance or shape of the outer surface of the workpiece surface. Due to the impact and cutting effect of the abrasive on the workpiece surface, the workpiece surface has a certain degree of cleanliness and different roughness, and the mechanical properties of the workpiece surface have been improved, Therefore, it improves the fatigue resistance of the workpiece, increases the adhesion between the workpiece and the coating, prolongs the durability of the coating film, and is also conducive to the leveling and decoration of the coating.

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Electroforming

Blackening

Electroforming is a process of depositing metal, alloy or composite material on the conductive master mold (core mold) by using the principle of metal ion cathodic electrodeposition, and separating it from the master mold to obtain products.

The main purpose of electroforming is to accurately reproduce fine, complex and special shape molds and workpieces that are difficult to process by other methods, such as the production of printing plates for banknotes and stamps, record stamps, typefaces, toy rotomolding molds, and model molds, Metal artwork replicas, mirrors, surface roughness samples, microporous filters, dials, electrodes for EDM, high-precision diamond grinding wheel substrates, etc.

The blackening treatment method of metal surface is a common method of chemical surface treatment. The blackening treatment of steel parts is also called bluing. The principle is to produce a layer of oxide film on the metal surface to form a dense oxide film protective layer to isolate the air and achieve the purpose of rust prevention. The blackening treatment can be used when the appearance requirements are not high.

At present, there are two common blackening methods: traditional alkaline heating blackening and later normal temperature blackening.

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Curving / Rolling

Anodizing

Curving is a forming method that the sheet metal is rolled by a machine roller and bent into a closed cylinder. It is generally combined with seamless welding to produce columnar metal products.

Anodizing is the electrochemical oxidation of metals or alloys. Aluminum and its alloys form a layer of oxide film on aluminum products (anode) due to the action of applied current under corresponding electrolyte and specific process conditions. Anodizing is generally used to color the surface of aluminum alloys.

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Deburring

Adhesive Backing

The processing methods of mechanical parts can be roughly divided into material removal processing, deformation processing, additional processing, etc. In all kinds of machining, the redundant parts derived from the machined parts that are inconsistent with the required shape and size are called burrs. Deburring is to remove the burrs or flash formed at the intersection of the part surface and the surface. Burr is a small thing, but it directly affects the quality of products. Therefore, products of all industries have certain requirements for burr removal.

Adhesive Backing is to brush or paste a layer of glue on the back of the metal to make the metal have the ability to stick to the body. It is usually used on metal logo, metal artifact, metal hull, metal panel and other products.

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