Despite its softness, graphite is one of the most challenging materials to process. When machining these parts, machinists must make several decisions regarding tools, coolant use, and personal safety. Graphite machining is the process of shaping, moulding, configuring, and cutting graphite material to create various parts and components for industrial purposes.
The types of tools utilized determine the success of graphite machining. To prevent chipping and breakouts, manufacturers utilize specifically developed cutting tools. In most situations, indexable carbide cutters with the most practical shapes for roughing at high rates of speed are employed.
What is Graphite, And What Are Its Types?
Graphite is a kind of carbon that contains carbon atoms organized in layers, which gives it its distinct features. Natural graphite is mined all over the world, although most of it is found in China, Brazil, Canada, and Madagascar. It is located in metamorphic and igneous rocks and is generated when carbon in the earth's crust is exposed to high pressure and temperature.
The carbon in synthetic graphite is of great purity and can endure high temperatures and corrosion. Calcined petroleum coke and coal tar pitch, which contain graphitizable carbon, are the primary elements used to produce synthetic graphite. The combined ingredients are mixed, heat-treated, moulded, and baked throughout the production process.
Machining cast iron and machining graphite processes are identical. Swarf, or fine chips, are removed as a fine powder. The tools used in the procedure do not grip the workpiece but cut it like ploughing snow. The compressive strength of graphite is muscular and may be kept in place by clamping force.
Graphite components are used in various sectors due to their chemical and physical qualities. It has a low thermal expansion coefficient, can be machined to tight tolerances and has excellent stability at high temperatures. Each of these qualities makes it ideal for specialized production applications.
Graphite has a wide range of applications, from the substance in pencil to the liner of nuclear reactors. Electrodes, brushes, and plates for dry cell batteries are made from crystalline flake graphite. In addition, the use of graphite in constructing electric vehicles is a significant new discovery.
Some of the types of graphite parts include:
Lubrication blocks are utilized in situations when wet lubricants cannot be used. They're primarily found in rotating equipment, including trunnion rolls, riding rings, tyres, and insert seals. Because of their weight, they are constantly in touch with the rolling surface, producing a thin layer of graphite. The significant reasons graphite is utilized for lubricating blocks are its wear resistance and long service life.
Bearings are manufactured to minimize friction between two surfaces. As a result, they provide load support when in touch with another moving item. Graphite is perfect for bearings because of its self-lubricating properties, extended service life, and ability to tolerate hostile conditions.
Graphite brushes are square and are used to conduct electricity via electric motors. They provide a consistent current shift between commutator segments and wear to preserve its condition. They are made from natural or synthetic graphite with a pitch or resin binding agent. Environmental variables will not taint graphite brushes.
While there are various uses for graphite in multiple industries, it still requires careful matching to ensure the best possible results. Factors that should be considered are:
Machined Graphite Processes of Various Types
Machined graphite parts and components come in various shapes and sizes. The procedure utilized to machine them is determined by the specifications of the element being created. Extruding, isostatically pressing, vibrating, and moulding are all ways of machining graphite.
Extruding is a typical procedure in the manufacturing of polymers. Graphite powder is combined with a binder, placed into a hopper, fed into the barrel of the extruder, and driven down the barrel to the die by a piston in the graphite production process. After leaving the extruder, the form is fired, impregnated, fired again, and graphitized at 2000C (3632F). Extruding graphite pieces is highly cost-effective.
Isostatic pressing delivers equal pressure on fine grain graphite powder. Workpieces are heat-treated after pressing to fully solidify, densify, alter, and purify them to create the final crystalline structure. The procedure can be carried out either cold or hot.
When high strength is not required, vibrated graphite processes large sizes of less dense graphite, making it a cost-effective production method. The finished product has a consistent structure and a low ash percentage. A pasty substance is poured into a mould, and a hefty plate is placed on top. The mould is vibrated until the pasty mass freezes to condense the material.
The molding procedure for graphite machining yields components with qualities comparable to those obtained by isostatic pressing. A graphite powder mixture is consistently squeezed into a mould and maintained there for a lengthy period. The resultant products lack the high-quality qualities of isostatic pressing but are appropriate for significant volume manufacturing runs of tiny parts like washers.
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SIGNIFICANCE OF AIR COMPRESSORS
Most of the air compressors in the world operate using standard, 3 faced induction motors. They are typically powered by electricity, natural gas or diesel. The primary goal of an air compressor is to pressurize the intake air for different industrial processes. The capability of a compressor in air pressurizing is measured in pounds per square inch gauge, widely known as PSIG, which is a comparison of barometric pressure and the pressure inside the tank. Barometric pressure is the amount of air pressure that is present in the atmosphere. As of 2020, the overall share of the Industrial Air Compressors Market was valued at around USD 31.21 Billion & it’s expected to increase with a CAGR of nearly 3.9% between 2021 & 2028.
The capacity of an air compressor is defined as the amount of air that can be produced at a specific PSIG. This output capacity is measured in terms of cubic feet/minute, or CFM. Capacity is regarded as one of the most prominent air compressor purchase factors, especially in the case if an individual intends to run multiple tools simultaneously.
When calculating the required CFM, one should consider the pressure level that is needed & especially if the plan is to use the compressed air continuously. For example, the high-pressure tools that always require constant or near-constant airflow need a higher capacity air compressor. For industrial automation machines that regularly use short bursts of air, like a nail gun, a lower capacity is perfectly suitable. The requirement for air compressors with multiple capacities is very high for the industries.
Compressor Tank Size
Most of the compressors contain a tank for storing the pressurized air until it is ready to use it. Large tanks mean that one can go longer without running the compressor motor, but an individual will have plenty of compressed air in hand to power the tools. Because the compressor is running less, an individual may see cost savings reflected in his/her energy bill.
Method of Lubrication
Whenever an air compressor contains some movable parts, these sorts of components require lubrication for the reduction of wear and tear & hence prolong the machine’s life. Lubricated air compressors typically inject an oil-based solution into the compression chamber that gets distributes it to the parts. These air compressors often require an oil filter to keep the residual oil out of the compressed air. For applications & industries that require 100 % oil-free compressed air, there is availability for oil-free compressors.
Rotary screw air compressor specifications generally refer to a positive displacement of the compression system powered by two counter-rotating helical screws, also known as rotors. Air is trapped between these two rotors & that trapped air decreases in volume as it moves, thus resulting in compressed air. Rotary screw compressor specifications, on the other hand, include both lubricated & oil-free compressors, which are designed for prolonged use. Although the rotary screw compressors are very much efficient & durable, they require some ongoing preventive maintenance by a trained professional to achieve the best results.
Although the air compressors are easy enough to use, still they can be some of the most complex pieces of machinery in the workplace. In the 1920s, Quincy Compressor was dedicated to helping the consumers to stay informed about the products that they choose & crafting machinery along with the air compressors, air dryers & other compressed air equipment that deliver uncompromising performance and reliability
To power AC motors, the electrical supply must be at full power for operating at high speed or variable power for operating at variable speed. Applications with changing loads advantage from the variable speed offered by an AC drive as less power is required at lesser loads and speeds. CM Industry Supply Automation shared this article to explain what AC drives in industrial automation are. You can check out Lenze Drive, KEB Drive, Elau Drive, Siemens Drive, Rexroth Drive, and many more manufacturer drive on our website.
An AC drive often called variable frequency drive short VFD is a power supply control and provisioning device used for AC motors. Since AC motors need frequency to turn, the drive should offer the essential energy waveform with adequate voltage to distribute the required current for producing magnetic flux within the motor.
For producing the required frequency waveform, an AC drive offered an AC voltage supply and corrects it to DC voltage, generally via a diode bridge. In addition, in the case of regenerative four-quadrant drive, then it changes it via insulated-gate bipolar transistors. This corrected power is stocked up in a capacitor bank as a component of a DC bus. This is considered the converting part of the drive.
The stored DC power in the capacitor bank is later supplied to switching equipment for creating the essential frequency. This AC power is distributed to the motor and makes it capable to spin at a required speed, which is usually measured in RPM (revolutions per minute).
The AC drive allows controlling the working characteristics of an AC motor to cut down energy utilized by the motor. This energy savings take place via adjusting or restricting the applied voltage and current while controlling acceleration or deceleration and while usual operation.
Applications of AC Drive
Conveyor, fans, and pump applications alone can produce numerous applications. Example of application includes a huge amount of flour blown via pipes for a bagging process, pumps handling a huge amount of soda via a bottling line, coal moving via conveyors, and many more.
From the plain air fan in the warehouse to the complication of energy storage devices, wastewater management, or water supply-AC motors operating at changing speeds play a vital role. As AC motors use huge electricity generated globally, using AC drives for restricting energy use can offer major savings.
What are the advantages of utilizing AC drives?
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