DEEP HOLE DRILLING INSERTS,LATHE MACHINE CUTTING TOOLS,CARBIDE INSERTS

When it comes to toys, most people probably think of LEGO. LEGO toys believe that everyone is particularly familiar with the world. It seems to be able to build a new world by using your imagination and putting LEGO blocks together. Many people have an endless demand for it. A small piece of building blocks, built out of a magical world. A world created by you, Tungsten Steel Inserts anything you want, as long as there is enough imagination and enough LEGO blocks.

But how to make so small and so many LEGO blocks, and still ensure that the clearance is less than 2 microns after each block is put together, and must also ensure a high enough rate of LEGO bricks to meet the standard? In fact, LEGO mainly relies on the injection molding process, which requires high injection molding tolerances, LEGO blocks are a typical example of the application of injection molding technology, you can still see the marks left after injection molding in the surface of LEGO blocks.

When it comes to injection molding, it is actually a very widely used process, Injection molding tolerances are critical because the toy industry is very demanding in terms of appearance and toy play experience, and most toys rely on this Cermet Inserts process to make it happen. Injection molding is a common manufacturing method in which heated liquid molten material is injected into a mold after passing through a long chamber, which is located at the end of the chamber and the fluid plastic is forced to cool through the nozzle, closing the grinder, and the semi-finished product exits the press as the plastic cools and cures. In this process, to get high precision as well as high tolerance of injection molded parts, we can start from several aspects.

To improve the plastic?injection?molding?tolerances, such as the form or basic structure of the mold, not only the parting surface of the mold should be considered for the molding and de-molding of the plastic part, but also the fluidity of the melt during the molding of the plastic part, and the distribution of the sprue, the location of the gate, the exhaust, the cooling or heating of the mold, etc. In injection molding, the mold cavity has to bear high pressure, if the mold stiffness is not enough, it will make the mold deformation and thus reduce the standard injection molding tolerances, so the influence of the cavity structure on the stiffness needs to be fully considered. It is necessary to overcome the wear and deformation of the mold, in which the manufacturing accuracy of the mold is the main factor that affects the injection molding tolerances.

Types and grades of plastics, such as plastic shrinkage, flow, moisture, and volatile content. Different plastic materials have different shrinkage differences and fluctuations. These can lead to fluctuations in injection molding tolerances.

Temperature、 pressure、 time. Due to the performance of the machinery itself and the practical experience of the operator, the process parameters often fluctuate, resulting in differences and changes in the shrinkage rate of the material, which affects the plastic injection molding tolerances.

The temperature and humidity of the environment, the degree of crystallization of molecules, and the orientation of fillers, or improper storage lead to expansion and post-shrinkage of molded products. The tolerance of injection molding can change due to the external environment.

For example, the shape and wall thickness of the workpiece, the measuring environment, and the reading habits of the measuring personnel can affect the tolerance of injection molded parts.

From these aspects, there are many subjective and objective factors that can affect the tolerances of injection molded parts, but it is obvious that injection molding still has many advantages, such as its ability to use a wide range of polymers as raw materials, it’s very smooth surface, its high production speed, and its excellent dimensional control system, which makes it easy to explain why LEGO bricks are manufactured by injection molding.

At any time WayKen can provide you with a professional rapid injection molding service, and we can do the tolerances of injection molded parts as tight as +/-0.0005” (+/-0.0127mm) to +/-0.002” (+/-0.05mm), and the min roughness to Ra 0.05μm, please feel free to contact us for your toy prototype.

Injection molding is one of the most popular methods for rapid manufacturing. The injection molding draft angle is a critical parameter in this process that has a significant impact on product quality.

In this article, our discussion will focus on draft angle injection molding. We will explain what is draft angle, why it is important, and what things you should keep in mind while designing molds for injection molding.

The injection molding draft angle is an essential geometric feature built into molds for injection molding. It is the taper, or degree of inclination, of the mold’s walls along the drawing direction.

As it is a feature of the mold, the draft angle is also visible on the component. Its unit of measurement is degrees.

Typically, engineers use an angle of around 1.5 degrees. However, it can range anywhere between 0.5-10 degrees for certain special applications.

It is easy to grasp the concept of what is the draft angle. Its benefits, however, are not as intuitive to understand and require some discussion. It is the most important among all molding angles. Small miscalculations can ruin the entire product line and even damage the injection molding equipment.

Without further ado, let us dive into the various reasons that make it an important injection molding parameter.

Part ejection is a crucial step in the molding process and a major reason for having the injection molding draft angle. Right before part ejection, the part is in contact with the walls of the mold. The contact stresses are high enough to deform the part from friction during ejection.

Therefore, it is desirable to minimize the impact of this frictional force. Engineers do this by including a draft in the mold. As soon as the part is pushed outwards by the ejector pins, the entire part pops out and loses contact with the mold walls. This lack of contact translates to no friction.

Without the draft angle, the part would rub against the surface of the mold throughout the ejection process, as seen in the figure. This is highly detrimental to the surface finish and manufacturing tolerance.

Moreover, the lack of friction also decreases the required ejection force, positively impacting the power requirements and also speeding up the ejection process.

Warping is one of the serious defects in injection molding processes. To explain what it is, refer to the figure in the previous section showing parts with and without draft angles.

When there is no draft angle by design, a vacuum might form in the empty space that appears when the part is ejecting. This vacuum causes the part to fold in on itself. This undesirable deformation is warping.

As can be seen, this issue is not present with an injection molding draft angle. As soon as the ejection process begins, the part separates from the mold and creates room for air to fill all cavities, preventing the vacuum from forming. Therefore, no warping occurs.

We briefly touched upon this advantage of draft angle injection molding in the previous section. Due to the draft, the part does not rub against the mold, which preserves the surface quality.

An important consideration here is the variation of the draft angle with the surface texture requirements. The draft angle needs to accommodate surface texture features as well in addition to the gross geometric features of the component.

This means that all craters/protrusions that make up the surface texture should also get enough space to detach from the mold wall. We will discuss more of this very soon.

The mold halves separate along the line of draw. This line of the draw is strategically placed to tackle critical errors such as deep drawing and flash.

In the case of a deep draw, the issue of the part getting stuck inside and to the mold is dealt with. The injection molding draft angle helps to reduce the negative effects of a deep draw, with a larger draft angle decreasing the risks.

Molding angles have a huge effect on injection mold costs. From the above discussion, we can deduce numerous ways the injection molding draft angle helps cut costs.

First of all, molds with draft angles produce parts with a better surface, less warping, and deep drawing issues. As a result, manufacturers incur fewer costs in part finishing and failed parts.

Additionally, maintenance costs are also much lower due to draft angles. The aforementioned friction damages the mold as well, which requires regular polishing and even replacement due to wear and tear.

Finally, the draft angle also saves costs by making the injection molding process quicker. It leads to quicker cooling cycles and part ejection.

The injection molding draft angle is a sensitive parameter that requires fine-tuning by mold designers. In this section, we present a list of recommendations for choosing the correct draft angle for specific applications.

The draft angle injection molding alters the thermal shrinkage of the molten resin/metal during the cooling cycle. This is because the shrinkage depends on the part geometry.

Shrinkage is always towards the geometry’s center of mass. This means that the outer faces of the part shrink away from the mold and separate from the walls while internal faces shrink inwards, onto the mold, gripping it tighter. As a result, the geometric dimensions of the part can change and affect its ability to form appropriate mechanical fits during assembly.

So, designers must take care that the draft angles included in their designs must not violate dimensional tolerances after shrinking. This specifically applies to all components and faces that are part of a mechanical fit.

We discussed the link between textures and injection molding draft angle before. The draft angle should create enough space so that the texture does not scrape off during ejection.

The rule is that the rougher the texture gets, the higher should the draft angle be. This assists in part ejection and preserving the quality of the texture.

Generally, for a mirror finish, a draft angle of 0.5 degrees will be appropriate. However, for every 0.1 mm increase in surface roughness, the draft angle should increase by 0.4 degrees. For exceptionally coarse patterns, engineers can opt for extreme draft angles up to 10 degrees as well.

The deeper the vertical features of the component get, the more prone it becomes to warping. Deeper parts have more empty spaces for vacuum generation during ejection. Thus, they warp more intensely, and more quickly.

The solution is quite straightforward – increase the injection molding draft angle for deeper features. The general rule of thumb is to add an additional degree of the draft for every inch in part depth. This rule may change slightly with part size and material but generally applies to the majority of injection molding jobs.

This is a highly efficient method for tackling components with features like deep pockets and cavities.

The core cavity approach is a technique that applies to parts where the outer side should be smooth while the inner side may remain a bit rough. This requirement is oftentimes for aesthetic purposes. For example, in protective enclosures, the outer surface is smooth and shiny for looks. It may also be a functional requirement if the outer part needs to slide or the inner part assembles with other components.

Either way, in the core Carbide Steel Inserts cavity method, the injection molding draft angle is slightly higher for the core so when the part shrinks, it shrinks into itself. In other words, its internal part sticks to the mold while the outer part completely detaches from the walls.

This way, the surface finish of the outer faces remains undamaged at the expense of higher roughness on the inner faces.

It can be a bit difficult to absorb so much information about molding angles in one sitting. To help our readers, here is a comprehensive list of tips and tricks:

• An injection molding draft angle of 1.5 degrees is recommended for general injection molding jobs.
• Incorporate the draft angles in both the cavity and core, with a slightly larger draft angle for the core.
• Add 1 degree of the draft for every inch increase in part depth. The depth, of course, means the dimension along Carbide Milling Inserts the direction of the drawing.
• Smooth surface textures require a small draft and rough textures require a high draft. Increase the draft by 0.4 degrees for every 0.1 mm increase in surface roughness.
• Add draft angles to all vertical features like walls, ribs, louvers, undercuts, etc.
• Use the core cavity approach if the outer face of the component needs to be smooth.
• If the component has features that require side drawing (additional drawing direction), include drafts in those features too.
• Hard materials with abrasive qualities warrant higher draft angles than soft, ductile materials.

This concludes our discussion on the questions of what is the draft angle, why it is beneficial, and what should you know about it. We hope that it was an interesting read and oriented your knowledge as injection molding designers. Are you have an injection molding project?

WayKen Rapid Manufacturing is an industrial expert in injection molding. Our rapid tooling services include exceptional mold designing and manufacturing, including highly accurate simulations and precise machining of molding angles. We provide a complete one-stop tooling solution with our advanced technologies, cost-effective manufacturing, and professional management.

We also provide extensive support to our clients right from the start. With our free-of-cost Design for Manufacturing (DFM) analyses, you can optimize your tooling designs before moving ahead with production. Today we invite you to contact us with your injection molding and tooling projects!

When to include a draft angle in the design process?

While the draft angle is strictly a requirement for flawless manufacturing, it affects part functionality. Hence, it is suggested to consider including the draft angle right at the beginning of the design process i.e. preliminary designing and prototype building.

Can I avoid draft angles?

It is not advisable to neglect draft angles in most cases due to the serious repercussions. It is an essential part of the manufacturing phase and affects the quality of production. In certain conditions such as the part being very small or tolerances being very low, a designer may choose to avoid draft angles, but even then it is not recommended.

What are positive drafts and negative drafts?

A positive draft angle is when the drafted features ‘taper in’ inside of the mold. That is, the features are wider at the base and narrower inside of the mold. A negative angle is the opposite of this. It ‘tapers outwards’ inside the mold.

Thermoset vs thermoplastic is one of the most significant comparisons in the manufacturing industry. Thermoplastic polymers were the most common types of polymers used for injection molding and other plastic machining processes. However, the surfacing of thermosetting plastics gave rise to worthy competition. Although these plastic polymers have some similarities, there are also several notable differences.

Thermoplastics are the best option in certain situations, while other cases require thermosets. The similarities of these polymers often make manufacturers use them for similar products. However, this may affect the quality Cemented Carbide Inserts and durability of the eventual product. Therefore, you must understand the differences between thermoset and thermoplastic to ensure you make the best decision.

This guide discusses the various differences between these polymers, detailing their features and suitable applications. Read on as we uncover the best plastic type for your project.

Thermosetting plastics have their polymers cross-linked during the curing process. As a result, they create an irreversible chemical bond. These polymers are typically liquid at room temperature but harden after heating or the addition of chemicals.

The cross-linking of these polymers prevents them from re-melting upon exposure to high temperatures. Therefore, a thermosetting plastic will retain its shape after being formed. This reason is why they are suitable for Carbide Turning Inserts high-heat applications.

Some of the common thermosets used in plastic part manufacturing include the following:

• Epoxy
• Melamine
• Phenolics
• Polyester
• Polyimides
• Polytetrafluoroethylene (PTFE)
• Polyurethanes
• Polyvinylidene fluoride (PVDF)
• Silicone
• Vinyl Ester

The impact resistance and high structural integrity of thermosets make them useful in the automotive, electronics, lighting, appliance, and energy industries.

Pros

• High strength-to-weight ratio
• Increased corrosion resistance
• Outstanding electrical insulation and dielectric strength
• Good dimensional stability
• High heat and temperature resistance
• Ensures flexible product design changes
• Low thermal conductivity
• Excellent aesthetic finishes
• Reduced tooling costs and production costs

Cons

• It is not recyclable.
• It can’t be reshaped or remolded.
• The rigidity of the material is not suitable for high-vibration applications.

Thermoplastics are resins that are solid at room temperature. The pellets soften upon heat, making them more fluid. This fluidity is due to the pellets crossing the glass transition temperature. Unlike thermosets, chemical bonding doesn’t occur in the processing of thermoplastics.

Thermoplastic polymers can be re-melted several times and formed into various shapes. You can also reheat, remold, and recycle these plastics without affecting their properties. They generally offer excellent elasticity and strength, and they resist shrinking. Therefore, these materials best suit processes like plastic extrusion, injection molding, and thermoforming.

There are several thermoplastics available today, each with different properties and uses. Some of the common ones are:

• Acetal Copolymer Polyoxymethylene
• Acetal Homopolymer Polyoxymethylene
• Acrylic
• Nylon
• Polycarbonate (PC)
• Polyethylene (PE)
• Polyethylene terephthalate (PET)
• Polypropylene (PP)
• Polystyrene (PS)
• Polyvinylchloride (PVC)
• Teflon

Pros

• Can be reshaped and remolded
• Highly recyclable
• Excellent quality aesthetic finish
• High impact and chemical resistance
• Excellent corrosion resistance
• Improved electrical insulation
• Enhanced anti-slip properties
• High flexibility

Cons

• Not suitable for some applications because it may soften upon heating.
• Relatively more expensive than thermosetting plastics.

Despite some similar features of these resins, there are several differences you must note. We will examine the major differences between thermoplastic and thermosetting plastic under the following headings:

Thermosets consist of heavily cross-linked lines of molecules. As mentioned earlier, this cross-linking gives a rigid molecular structure. You can heat them the first time and shape them into any structure you desire. However, they ultimately become solid and stiff. This stiffness is permanent, preventing them from being reshaped.

On the other hand, thermoplastics do not have cross-linked molecular chains. There are no chemical bonds connecting the chains, only intermolecular forces. As a result, their macromolecules are majorly located beside or next to one another. Upon application of high heat, the chains slightly shift against one another. Therefore, plastic can easily be reshaped and remodeled.

In material selection, it is crucial to consider physical and chemical properties to ensure optimum performance. Here’s a detailed thermoset vs thermoplastic comparison of their features:

2.1 Melting Point

The main difference between thermosetting plastics and thermoplastics is related to their behaviors when heated. Thermosets have melting points higher than degradation temperature, while that of thermoplastics is lower.

When heated after curing, thermosets retain their solid shape. On the other hand, thermoplastics will melt or decompose upon further heating. Therefore, thermosetting plastics have higher melting points than thermoplastics. This is why manufacturers use thermoplastics for recyclable components.

2.2 Corrosion Resistance

Both types of plastic polymers can adequately resist rusting or corrosion. Therefore, they are suitable for outdoor applications and can come in contact with corrosive media. However, thermoplastics can resist chemical attacks than thermosets. Thus, they are more corrosion-resistant.

2.3 Durability

If you’re looking to manufacture automotive or electrical appliances, you must ensure heat resistance and durability. Thermosets are highly durable than their counterpart. These plastic polymers are often more lightweight, with excellent strength, toughness, and impact resistance.

You can even further strengthen them with reinforcing materials such as fiberglass and carbon. Their excellent structural benefits and dimensional stability makes them more suitable than thermoplastics in terms of durability.

The thermoset vs thermoplastic chart below compares the physical and chemical properties of these plastics:

The processing of thermoplastics can be done using various methods, including injection molding, extrusion molding, vacuum forming, and thermoforming. The machinist feeds the granular material into the mold, often using spherical resins of about 3 mm diameter. Then the resins are heated at high temperatures to the melting point.

Thermoplastics are excellent thermal insulators. Therefore, it takes longer to cool them than other plastics. Most manufacturers use rapid cooling to get a high output rate by plunging them into water baths or spraying them with cold water. Upon cooling, the plastic material shrinks, affecting the material’s crystallization and internal structure. Thus, it is essential to specify the shrinkage rate for thermoplastics.

On the other hand, the processing of thermosetting plastics occurs in their liquid forms. The major processes used are Resin Transfer Molding (RTM) and Reaction Injection Molding (RIM). The curing process often includes inhibitors, curing agents, plasticizers, hardeners, or fillers. The choice of reinforcements will depend on the desired outcome.

Thermoplastics are popular options for providing top-quality finishes. However, the RTM and RIM processes, as discussed above, make the finishing of thermosets unique. With these techniques, you have unique chances of achieving premium aesthetics. They allow direct spraying into the mold before the injection of the thermosetting plastic resin.

These processes also allow in-mold painting and coating. With this, stronger bonds will be formed between the plastic surface and the paint. Consequently, you can ensure proper adhesion and prevent cracking, chipping, flaking, and other plastic fabrication defects.

In addition, thermosetting examples, such as epoxy, phenolics, silicones, etc., are suitable for high- and low-gloss surface finishes. Painted parts made with thermosets often present finely detailed textures. Their excellent flowability helps them accommodate delicate aesthetic touches.

Thermoplastics are usually less expensive than thermosetting plastics regarding overall production costs. However, it is important to consider the factors affecting plastic prototyping. Asides from the material itself, you must consider the tooling cost, labor cost, production time, and finishing choice.

Thermoset plastics are used in many industries because it is relatively more economical. It also ensures the products meet desired specifications. Thermosets have an excellent combination of thermal stability, structural robustness, and chemical resistance.

The resins are also flexible enough to ensure the seamless formation of complex geometries. As a result, they are excellent substitutes for some metal materials. The RTM and RIM techniques also ensure considerable consistency in their fabrication. Their typical applications include the following:

• Chemical generating and processing tools, including piping, cell covers, and fittings
• Medical and electrical components and housings
• Housings, panels, and doors for transportation and heavy construction
• Automotive parts for cars and tractors
• Components for military vehicles

On the other hand, the applications of thermoplastics vary for different industries. Their high chemical and corrosion resistance makes them good metal substitutes. However, you must note that they do not withstand as much heat as thermosets.

Thermoplastics are suitable raw materials for various industries, including automotive, chemical, biomedical, electronic, and food & beverage industries. Some of their applications are:

• Constructing industrial machining components
• Piping systems for chemicals
• Laboratory equipment
• Electrical or electronics insulating and encapsulating materials
• Non-stick kitchenware
• Protective coverings for rigid tools
• Liquid storage tanks

Both thermoplastic and thermosetting plastic have a wide selection of materials with various applications. These polymers are top choices for your products. However, the option you choose will depend mainly on the application of your desired product. Remember that wrong material selection can affect the functionality of a product, even if it is well-designed.

When choosing a material, you must carefully consider the impact resistance, strength, heat resistance, and other factors. For instance, thermosets are more suitable for applications where heat is a factor, including electrical appliances and housings. They are also ideal for chemical processing equipment because of their heat & chemical resistance as well as their excellent structural integrity.

Thermoplastics are best used for products that will be exposed to corrosive materials. They also help produce high-volume parts easily and at competitive pricing. You can also get detailed geometric shapes with thermoplastics, making them good metal substitutes. They are also recyclable and reused, which can reduce long-term costs.

Thermoplastic and thermosetting plastic has several variations in characteristics, recyclability, costs, and other features. Therefore, they are ideal for different applications based on required physical and chemical properties. While thermosets are suitable for high-heat applications, thermoplastics are more renowned for their corrosion resistance and recyclability.

Different applications require the selection of the right materials. Therefore, you should go through the features discussed earlier and pick the best plastic material for your project. Expert engineers at WayKen are ready to assist you with material selection. We also use advanced machines for plastic machining and reduction of lead times. Contact us to get high-quality plastic parts today!

Why are thermosetting plastics harder than thermoplastics?

Thermosets are harder than thermoplastics because of their three-dimensional cross-linked networks created during curing. The polymer chains maintain their strong covalent bonds and shape. Their higher cross-linking density gives them higher mechanical strength and hardness. Thus, they are preferred for their structural integrity and heat resistance.

Is thermoplastic toxic?

Any raw material can be potentially toxic, depending on various factors. Thermoplastic polymers are not inherently toxic, and they are safe for several applications, including biomedical devices.

Which thermoplastics or thermosets can resist temperature better?

Thermosets can generally resist higher temperatures than thermoplastics. Furthermore, they have strong covalent cross-links between their polymer chains. Therefore, they cannot soften upon further heating. As a result, thermosets have more stability than their counterparts.

A bead blast finish is an excellent surface finish suitable for a wide range of applications. It stems under the broad umbrella of “media blasting,” one of the most popular surface finishes available for custom machined parts. Besides bead blasting, other media blasting techniques include abrasive planting and sandblasting, each having its benefits and drawbacks.

This article will focus on bead blast finish and everything it tungsten carbide inserts entails. We will explain the principle behind the process and the various tools used to achieve the best bead blast surface finish. You will also learn the advantages and setbacks of this surface finish to help you make the right decision for your project. Let’s get to it!

Bead blasting involves the release of fine glass or steel beads at high pressure to finish a component’s surface. During the process, a high-pressured tool shoots bead-shaped media towards the surface.

This process occurs in a well-monitored bead blasting cabinet, leaving a shiny, smooth, clean surface. Manufacturers often use a bead blast finish for metals, plastics, rubber, and glass materials to improve their appearance and physical properties.

If you’re familiar with other abrasive blasting methods, then you have an idea of bead blasting Carbide Milling Inserts principles. Generally, it involves projecting spherical or bead-shaped media against the surface of a workpiece. The impact of the jagged media leaves a smooth, uniform finish on the component. The dimpling of the bead blasting media gives the eventual bead blast surface finish.

Bead blasting is also an excellent option when you’re looking for rough yet consistent finishes. Fine glass media can leave “dull” or “satin” finishes on your 3D printed or machined parts’ surfaces, making it a top choice for post-finishing services. On the other hand, you can use coarse glass media to give a uniform “rough” bead blasting finish.

Asides from leaving uniform surface finishes, bead blasting also help mask imperfections on workpiece’s surfaces. While some parts’ finishing techniques may leave components with darker surfaces, the bead blast finish keeps the base color of the substrate. As a result, you will get parts with brighter surfaces.

The main difference between bead blasting and sandblasting lies in the material used in the blasting process and the safety concerns associated. While both work with similar principles, using them in differing circumstances is better. The glass bead blasting technique uses spherical glass media at high pressure while sandblasting utilizes silica sand for the finishing process.

Sandblasting is a much faster technique than bead blasting. However, a bead blast surface finish is much gentler on the material, effectively stripping it without damaging the material underneath. This process does not affect the component’s dimensions, giving a more polished surface with optimum quality.

On the other hand, sandblasting is much harsher. It propels fine bits of sand at extreme velocities to clean or etch metal surfaces. Thus, it creates lots of sand or silica dust that can harm the operator’s health when inhaled. Prolonged inhalation may lead to a health condition called silicosis.

Furthermore, sand blasting may reshape the underlying component if not regulated properly, changing the part’s dimension. Therefore, monitoring the process carefully and wearing preventive gear during sandblasting is essential.

The key to a successful bead blasting process is efficient tooling that serves the right purposes. Let’s look at the different tools required to get the best results.

The media itself is an essential bead blasting material. Machinists generally use two types of beads for a bead blast surface finish. They are glass beads and steel beads.

Glass beads are made from lead-free, soda-lime glass designed to come in spherical shapes. These materials are more environmentally friendly since you can recycle them over 30 times. They are also softer on components’ surfaces.

On the other hand, steel shots come from molten steel designed into round objects with round molds. They are cost-effective alternatives because they are durable and allow several recycling rounds. Steel beads are more effective for polishing or removing unwanted textures on metal surfaces.

This is where the whole blasting process occurs. You must choose a high-quality bead blaster cabinet that can ensure the safety of the personnel carrying out the operation. At the same time, the cabinet should not compromise the quality of results.

A typical bead blasting machine must be constructed with a solid material. Steel is the perfect choice in this case because it is a sturdy and durable material. Cabinets made from steel usually last longer and can withstand the high level of pressure that comes with the process.

Likewise, you don’t want your cabinet to have weak legs and disrupt the finishing process. The legs of the glass bead blaster cabinet must be strong enough to support the weight of the cabinet, the bead blasting media, and the workpieces. Weak legs will constantly shake and be unsteady, and this can be dangerous to the operator. Moreover, having your tool break down during the bead blast finish will be daunting.

So, what are the essential components of a good glass bead blasting cabinet?

●Consistent Cabinet Sealing

The cabinet’s sealing on the inside must be very good. Remains or debris from abrasive blasting finishes can be dangerous to the health. Therefore, the seals must prevent the dust or debris from leaving the cabinet.

●View Window Protection

Your bead blaster cabinet should have larger windows to help observe workpieces adequately as you work inside the cabinet. However, what’s more important than the window’s size is its protection. Some glass beads tend to cause frosting on the glass after some time.

As a result, they may impair visibility, affecting the quality of results. Therefore, you should put replaceable protective sheets on your cabinet’s view window for longer blasting with no issue.

A bead blast finish cannot occur without the blasting gun. Therefore, it is a vital component to always keep in mind. There are several blast gun designs, and their operations also differ. While some work using a hand pedal, others work via a foot pedal.

The choice of blast gun is up to you or the operator. However, if your project requires long blasting sessions, you should consider blast guns with foot pedals. They are more comfortable and cause less strain on the operator.

Safety and comfort are a priority for every bead blasting process. Blasting gloves are among the protective gear to ensure adequate protection of the operator. The gloves often come together with the cabinet. Since you may be holding the blast gun in your hands, you want to protect them from residual harm. These gloves also help you get a good grip on the gun.

Without changing the component’s dimensions, bead blast finish facilitates the creation of uniform surface finishes. As opposed to other media, this method is not aggressive. Additionally, it works excellently with a variety of materials, making it appropriate for various industries.

Bead blast surface finishing is a technique manufacturers use to increase component longevity. This finishing procedure is adaptable and works with many other manufacturing procedures. Smaller beads, for instance, are useful in lighter processes requiring fine details.

However, when bead blasting stainless steel or aluminum, medium-sized beads are the ideal option. They are popular for their capacity to cover up surface defects on components. Finally, larger beads are preferred for cleaning and deburring rough surfaces on automotive parts and other metal castings.

Generally, bead blasting is a versatile process that helps cover a wide range of applications, including the following:

• Peening – to help metals resist fatigue and prevent cracking
• Deburring – smoothening the rough edges or ridges of metals
• Cosmetic finishing – adding aesthetic features to components
• Preparing metal surfaces for other secondary finishes like powder coating and painting
• Polishing materials such as aluminum, stainless steel, and cast iron
• Removing paint, rust, scale, and calcium deposits

Bead blast finish is also suitable for a wide range of applications for several industries, including:

• Aircraft components as preparation for painting
• Automotive parts before adding brand new paint
• Military components
• Aluminum parts for medical applications

The bead blast surface finish gives you a non-directional smooth and textured surface that is also aesthetically pleasing. This surface finishing technique is versatile, working on various materials, including aluminum, stainless steel, titanium, copper, brass, and plastics.

Despite its usefulness and versatility, you should also consider some of the downsides of bead blasting. This section will highlight the advantages and disadvantages of using bead blasting for your project.

• It is one of the most affordable and less aggressive surface finishes available.
• Bead blasting is much safer than several other blasting processes.
• The blasting process does not change the underlying color of the workpiece, thereby giving you a brighter finish.
• Bead blasting media like glass beads can be recycled up to 30 times and reused before replacement.
• Since the glass beads come from lead-free material, the eco-friendly process does not leave any harmful residues.
• If you desire, you can mask some surfaces of the component from the bead blaster.
• It is an excellent surface finishing option for intricate components.

• It may not be suitable for applications that require strict tight tolerances.
• Blasting tougher materials may take longer.
• Using glass beads may not give room for paint adherence.
• It can be labor intensive since it is operated manually.

From the several bead blasting media available to the pressure used during the process, many variables can affect the final appearance of bead blasted parts. Therefore, you must provide adequate specifications to control these variables for quality and consistent results.

Let’s go over the best practices and tips for better control of the bead blast finishing process and excellent finishes.

The kind of media you use will determine the feel and look of your eventual bead blast finish. For instance, fine glass beads will give you a uniform, satin finish, while coarse glass beads give a rough finish. On the other hand, steel shots are best used for polishing and removing unwanted textures from materials.

The lower the grit of your abrasive material, the coarser the particles will be. In contrast, higher grits have finer particles. Generally, media sizes can be very fine, fine, medium, or coarse. Your choice will depend on the result you wish to get. You should include this information in your part drawings or order notes when you request a quote.

The nature of the bead blasting process will directly impact the surface roughness of the component. Sometimes, it is difficult to keep to tight surface roughness requirements when using bead blast surface finish. Therefore, keeping the surface roughness at nothing lower than 32 μin Ra if you need a smooth part is preferable.

Suppose your component has surfaces or features that should not have the bead blast finish. In that case, you should include masking callouts for these features. Examples of such features are O-ring grooves and sealing surfaces. You may also add masking requirements for small pitch threaded features.

You also want to keep the pressure of the bead blaster as low as possible. Glass beads often give the best results at low pressures. Therefore, you want to start with about 50 PSI. This will increase the lifespan of your beads and will give you the optimum bead blasting finish.

Smashing the beads on the component at extremely high pressures may crush the beads and increase total production costs. Likewise, you tend to produce excess debris and dust, which may be dangerous to the operator or deposit on the component’s surface.

When bead blasting aluminum, you must first strip off its oxide layer because it may be too difficult to polish. Glass beads won’t help get rid of this layer. Therefore, you will need to use sharp cutting material to remove the oxide layer or rust.

A bead blast finish is ideal for getting semi-polish, satin-like finishes on your parts. It is a versatile surface finishing technique that works well on various materials and is suitable for an extensive list of applications. It is also less aggressive and relatively affordable, making it a great choice for your project.

However, it would be best to work with a reliable partner to get the best results from a bead blast surface finish. WayKen offers high-quality parts finishing services at very competitive prices. We are committed to meeting the needs of parts requiring a variety of surface finishes. Contact us to get expert advice for your next project. If you’re ready to work with us, request a quote today!

What is the purpose of the bead blast finish?

Bead blasting is flexible and versatile. It can help clean the surface of your component to create a uniform, dull or satin-like surface texture and improve its overall appearance.

Is glass bead blasting safe?

Using glass beads is safer than most other bead blasting media. They do not produce silica dust or debris that may cause harm to the operator. They are also gentle on the part’s surface and won’t change its dimension.

WNMG Insert: Double-sided trigon insert with a stable cutting edge designed for medium- & semi-roughing on steel and cast iron. (-) Trigon Inserts with Two Sides for General Use(+).

Finish cutting (FH) is the First choice for carbon steel, alloy steel, and stainless steel finishing. Chip breaker with two sides. Even at shallow depths of cut, chip control is stable

Cut depth: up to 1m

0.08 to 0.2mm feed rate

LM?stands for light cutting. Burr control is excellent. Because the sharpness qualities and cutting edge strength are optimized with varying rake angles, the incidence of burrs is dramatically reduced.

Cut depth: 0.7 – 2.0

Feeding frequency: 0.10 – 0.40

LP – Very light cutting. Butterfly protrusions are tailored to specific cutting circumstances. Chips curl upwards, reducing cutting resistance and resulting in better surface finishes. The breaker protrusion is exceptionally resistant to wear even during high-speed milling, allowing for lengthy durations of steady chip breaking. Excels at copy machining: has a sharp edge shape that produces good chip breaking during copy machining and reverses direction face machining.

Depth of cut: 0.3 – 2.0

Feed rate: 0.10 – 0.40

GM – The primary LM and MM chipbreaker’s sub breaker. For light to medium cutting, it has excellent notch resistance.

Cut depth: 1.0 – 3.5

Feed rate: 0.10 – 0.35

MA – For medium carbon and alloy steel cutting. Chip breaker has two sides and a positive land for the strong cutting action.

Cut depth: 0.08 to 4mm

0.2 to 0.5mm

MP feed rate – Medium slicing. It is suitable for various copy-turning situations, removing the need for different insert kinds. The inner side of the butterfly protrusion features a sharp gradient, which improves chip-breaking efficiency on minor cuts.

Cut depth: 0.3 – 4.0

Feed rate: 0.16 – 0.50

MS – Medium cutting rate for difficult-to-machine materials. Ideal for nickel-based alloys, titanium, and stainless steel.

Cut depth: 0.40-1.8

Feed rate: 0.08 – 0.20

MW – Wiper inserts for medium carbon and alloy steel cutting. Chipbreaker has two sides. The wiper can double the feed rate. The large chip pocket reduces jamming.

Cut depth: 0.9 – 4.0

Rough cutting feed rate: 0.20 – 0.60

RM Outstanding fracture resistance. High cutting edge stability is accomplished during interrupted machining by adjusting the land angle and honing geometry.

Cut depth: 2.5 – 6.0

Rough cutting feed rate: 0.25 – 0.55

RP The peninsular protrusion has been optimized for rough cutting. The increasingly slanted cutting face decreases crater wear and prevents clogging. High fracture resistance: the cutting flute has a robust flat-land form and a large chip pocket to prevent clogging and fracturing during chamfering.

Cut depth: 1.5 – 6.0

Feeding frequency: 0.25 – 0.60

Include problems.

What factors should a shop consider when selecting an indexable insert for a cutting application? In many circumstances, this is likely not how the decision is reached.

Instead of defaulting to the familiar, the best way is to examine the cutting process in detail and then pick an insert with the appropriate features to satisfy the needs and requirements of that application. Insert providers might be of great assistance in this respect. Their expertise can guide you to an insert that is ideal for a specific work but will also assist maximize productivity and tool life.

Before deciding on the best insert, businesses should assess if a detachable cutting tip is a better solution for a project than a reliable tool. One of the most appealing aspects of inserts is that they typically have more than one cutting edge. When a cutting edge becomes worn, it can be replaced by rotating or flipping the insert, commonly known as indexing, to a new edge.

However, indexable inserts are not as hard as solid tools and hence are not as precise.

When the choice to use an indexable insert is made, retailers are faced with a plethora of possibilities. Decide what you want to achieve with the insert as an excellent place to start selecting. While productivity may be the key concern in certain organizations, others may value flexibility more and prefer an insert that can be used to produce several sorts of comparable components, he noted.

Another factor to consider early in the insert selection process is the application, namely, the material to be machined.

Modern cutting tools are material-specific, so you can’t just pick an insert grade that works well in steel and expect it’ll work well in stainless, superalloys, or aluminum.”

Toolmakers provide several insert grades — from more wear-resistant to harder — and geometries to handle a wide range of materials, as well as material circumstances such as hardness and whether a material is cast or forged.

If you’re (cutting) a clean or pre-machined material, your grade option will be different than if you’re (cutting) a cast or forged component. Furthermore, geometry choices for a cast component will differ from that of a pre-machined component.”

Shops should also consider the machines in which an insert will be carbide turning inserts employed.

Some machines have horsepower restrictions, while others have spindle rpm restrictions. If you don’t consider things, you can pick a carbide grade that has to operate at a higher rpm to be effective but can’t because of machine restrictions.”

Helical-flute indexable thread mills (bottom) are quicker and more efficient than straight-flute indexable thread mills (top), and they typically wear significantly less.

Aside from machine capabilities, shops should examine the overall machining setup and assess its stiffness and stability. It comprises the machine’s steadiness and the tool holding or work holding.

“If you can’t clamp a big section of the component, you wouldn’t pick a greater radius insert since it may (raise) tool pressure, causing chatter or lifting the part out of the work holding.”

It claims that if the tool holding or work holding configuration is not firm, the outcome will be noise.

And if you have noise and a too-hard insert substrate, you have a condition that is considerably more prone to insert failure.

It exemplifies a crucial but perplexing aspect of insert selection: The most durable, wear-resistant insert substrate is not necessarily the best solution for a given application. Consider a case where an insert must be selected to cut forged material in hard places.

Because the tougher the insert, the more brittle it is, running into a difficult cut section might result in catastrophic insert failure.”

Similarly, the most wear-resistant grade for applications with unstable settings is usually not the best choice.

Instead, you’ll probably have to graduate to a higher grade to deal with the vibration caused by the instabilities.

The machining speed of an application is another key consideration in grade selection.

In general, he explained, the goal is to run as quickly as possible to maximize productivity but not run so fast that the pace drastically lowers tool life.

Incorrect speed and feed settings with a certain insert might result in poor surface quality and chip control. He also mentioned that inserts with bigger nose radiuses demand a higher feed rate. Generally, the bigger the nose radius, the higher the feed rate.

“If there is chatter, the natural tendency is to reduce the stream rate,” he explained. “However, in this circumstance, you should do the exact opposite. Chatter and poor surface finishes may result if you do not employ a greater feed rate with a bigger nose radius.”

Andersson identifies a few different types of errors that frequently occur when choosing inserts for a document. One’s first focus should be on selecting the optimal grade for a given application; only after that should one think about the many possible geometries with that grade.

Never consider the grade and geometry two different subjects since you may use geometry to help reinforce the grade.

Take, for example, the level of hardness possessed by an insert.

You can measure a material’s mechanical toughness attributes, but the results don’t matter that much. What is important is how the combination of grade and geometry reacts in the machine used by the end-user. And if you choose an exceptionally robust geometry, you will experience an increase in toughness behavior.

Insert microgeometry, also known as edge line condition, and what he refers to as “macro geometry,” which is the form or topography of the top side of the insert, are both examples of factors that fall under the umbrella of “geometry.” In most contexts, the latter is referred to as the chip breaker.

If you look in the catalog of any manufacturer, you’ll find that one material, like steel, typically comes in various grades and chip breakers from which to choose.

Another typical error we mentioned was the misconception that an insert with more cutting edges is invariably the superior option. That would suggest, for instance, that a WNMG insert with six edges is naturally a superior choice to a CNMG insert with only four edges.

When you first hear about the WNMG, your first instinct is probably to assume that the cost per edge would be reduced. However, this is not the case.

He said that the reason for this is because how the WNMG is positioned in its pocket is a somewhat fragile design that permits insert movement while the pocket is machined. Vibration is the direct effect, and this vibration leads to higher wear and a shorter life for the tool. Therefore, in many situations, a CNMG would cut the same number of components over time as a WNMG would.

The demand made by shops for inserts capable of cutting various distinct materials is seen as problematic by industry professionals.

In many situations, four-edge CNMG inserts can cut just as many pieces as their six-edge WNMG counterparts. That is because both types of inserts have two cutting edges.

“The more you utilize the same grade and geometry for various applications, the more compromises you impose. As a result, you start incurring penalties in tool life and chip control, ultimately setting yourself up for failure.”

Shops that choose a general-purpose grade and chip breaker also reduce their cycle time, which is counterintuitive for those seeking to optimize their operations.

On the other hand, several types of machine shops require their equipment to be adaptable enough to handle various machining circumstances.

Two-sided trigon inserts(+). Double-sided trigon inserts for steel and cast iron. First choice for finishing carbon, alloy, and stainless steel. The medium cutting rate for hard materials. Peninsular protrusion for rough cutting.

Slanted cutting face reduces crater wear and clogging. The cutting flute’s sturdy flat-land design and big chip pocket minimize clogs and fractures during chamfering. 1.5-6.0 cut depth, 0.25-0.60 feed rate. Inserts offer many cutting edges, which is a plus. Shops should examine which machines will need an insert. Some machines have horsepower and spindle rpm limits. The most robust, wear-resistant insert substrate isn’t always the greatest. To increase productivity, run as rapidly as feasible without reducing tool life. Six-edged WNMG inserts are better than four-edged ones, argues Andersson. Andersson urges never to separate grade and geometry. Microgeometry and macro geometry fall under “geometry.” A four-edge CNMG can cut as many pieces as a WNMG. Both feature two cutting edges. Additional applications using the same grade and geometry mean more tradeoffs.