METAL CUTTING metal cutting tools metalcuttingtools metal working tools sheet metal tools

Cutting and axis sync demonstration on ZPS MCV1210 5 axis

2008-02-09T05:57:00.000-08:00

Cutting and axis sync demonstration on ZPS MCV1210 5 axis

Laser Cutting IPK Dino Promo

2008-02-09T05:55:00.000-08:00

In 1999 IPK Broadcast Systems in Reading decided they wanted a promo video showing their metalwork abilities at the IBC trade show in Amsterdam.

The firm had just recently purchased a LVD laser cutting machine, and since it looked very impressive when running it was decided to make a video showing this off as much as possible.

One of the promotional tools IPK was using was a dinosaur model cut from steel using the laser cutter - which were also available on the stand at IBC - so we wanted to include this in the story as well as more standard metalworking. An idea was born that the dinosaur would take us through the process, now all I had to do was work out how to bring a metal dinosaur to life and have it wondering around the factory!

It was filmed using a Sony TRV900 (in it's not very good widescreen mode), and edited together with Premeire on a Mirovideo DC30+ capture card. The model dinosaur was filmed in front of my TV with a blue picture on it, and the workshop shot involved some photoshop work to produce a key.

The dinosaur was cut from 2mm steel, and I think the latch was cut from aluminium. Machines used were a LVD Helius 2KW laser profiler, and a LVD Bending machine. Unfortunately IPK has now stopped trading

Woodworking Tungsten Non Ferrous Carbide Bur Cutting Tool

2008-02-09T05:53:00.000-08:00

Woodworking Tungsten Non Ferrous Carbide Bur Cutting Tool

Creating a Surface Development Pattern

2008-02-09T05:52:00.000-08:00

Creating a Surface Development Pattern

In this video Fay Butler will be making a surface development pattern out of simple drawing paper. The part he will be patterning is a high crown part. This part is an antique car wheel well, which is similar to what a full motorcycle fender might be. The paper allows me to see how to brake up the part into pieces, with the minimum weld seams and pieces. It will show me where the compound curve is. He will be using magnets to hold the paper in place

The Reverse Curve

2008-02-09T05:51:00.001-08:00

The Reverse Curve

Fay Butler talks about and demonstrates the Reverse Curve. Reverse curves are developed by stretching from the edge of a sheet. In the video I will show two examples of a linear stretch die and their use in a home made air planishing hammer using a Milwaukee fender hammer head. The die is placed in the lower anvil perpendicular to the sheet edge, held in registration by hose clamps or electrical tape.

Smoothing on the Power Hammer

2008-02-09T05:49:00.000-08:00

Fay Butler demonstrates how to smooth a piece of sheet metal using the Yoder Power Hammer. Smoothing is accomplished by using two hardened steel dies; a flat surface on the top and some radius on the bottom. By averaging out the curves on the part, a larger radius bottom die can often be used. Transitioning a radius highlight line into a flat will require some stretching of the flat area. Checking the part to your pattern may indicate areas requiring more form and/or shaping.

Layout and Cutting a Blank

2008-02-09T05:48:00.000-08:00

In this video Fay Butler will show how he uses the surface development paper pattern to lay out an accurate blank. By taking the paper with the tucks in it and opening them out, the paper will lay onto a flat sheet of metal. Using this paper pattern, important information such as holes, edges, beads, and highlight lines can be transferred to the metal. This is accomplished using simple layout tools such as a spring loaded prick punch, scribe, or marked lines.

Thread Cutting Closeup

2008-02-09T05:47:00.000-08:00

Cutting 1/2-20 threads with my lathe.
Camera is mounted on the tool post

Using Metal Shears: How To Cut and Bend Sheet Metal : Cutting Procedure: Using Squaring Shears

2008-02-09T05:46:00.000-08:00

Learn tips and techniques on how to use metal shears, including the cutting procedure for using squaring shears in this free how-to video clip

Using Metal Shears: How To Cut and Bend Sheet Metal : Cutting Procedure: Using Foot-Operated Metal Shears

2008-02-09T05:44:00.000-08:00

Learn tips and techniques on how to use metal shears, including cutting procedure for using foot-operated metal shears in this free how-to video clip

Cutting a chainsaw

2008-02-09T05:42:00.000-08:00

Ever been tempted to see what else you can cut with a plasma torch? See what happens when we cut up a chainsaw with plasma. Check out 101 Uses for a Thermal Cutting Tool.

Milwaukee Metal Saw Tips

2008-02-09T05:41:00.000-08:00

Tips from Milwaukee Electric Tool on how to extend the life of the blade and tool of their 6370-21 metal cutting saw

How to Use a Reciprocating Saw: Free Power Tool Videos : Cutting Metal: How to Operate a Reciprocating Saw

2008-02-09T05:39:00.000-08:00

How to Use a Reciprocating Saw: Free Power Tool Videos : Cutting Metal: How to Operate a Reciprocating Saw
Cutting Metal: Learn how to operate a reciprocating saw in this free instructional video series on power tools. Get wood & metal cutting tips & techniques, as well as recip saw safety guidelines

Flange

2008-01-31T02:42:00.000-08:00

A flange is an external or internal rib, or rim (lip), for strength, as the flange of an iron beam or I-beam; or for a guide, as the flange of a train wheel; or for attachment to another object, as the flange on the end of a pipe, steam cylinder, etc, or on the lens mount of a camera. Thus a flanged rail is a rail with a flange on one side to keep wheels, etc., from running off. The term "flange" is also used for a kind of tool used to form flanges.

Microwave RF

2008-01-29T03:00:00.000-08:00

In microwave telecommunications, a flange is a type of cable joint which allows different types of waveguide to connect.

Several different microwave RF flange types exist.

CAR flange
CBR flange
OPC flange
PAR flange
PBJ flange
PBR flange
PDR flange
UAR flange
UBR flange
UDR flange
UPX flange

ASME/ANSI Pipe Flanges

2008-01-29T02:54:00.000-08:00

Pipe flanges that are made to standards called out by ASME/ANSI B16.5 or ASME/ANSI B16.47 are typically made from forged materials and have machined surfaces. They are typically in "Pressure Classes" such as 150#, 300#, 600#, 900# 1500#; however, ASME B16.47 still recognizes the 75# or "Class 75" flange for certain low pressure and low temperature applications. These "Pressure Classes" have both pressure and temperature ratings for specific materials.

The flange faces are made to standardized dimensions and are typically "flat face" "raised face" "tongue and grove" or "ring joint" styles, although other obscure styles may be permitted.

Flange designs are available as "welding neck" "slip-on" "lap joint" "socket weld" "threaded" and also "blind flange".

The gasket type and bolt type are generally specified by the standard(s); however, sometimes the standards refer to the ASME Boiler and Pressure Vessel Code (B&PVC) for details ( see ASME Code Section VIII Division 1 - Appendix 2 ). These flanges are recognized by ASME Pipe Codes such as ASME B31.1 Power Piping, and ASME B31.3 Process Piping.

Materials for flanges are usually under ASME designation: SA-105 (Specification for Carbon Steel Forgings for Piping Applications) , SA-266 (Specification for Carbon Steel Forgings for Pressure Vessel Components) or SA-182 (Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service).

Plumbing or Piping

2008-01-29T02:45:00.000-08:00

Although flange generally refers to the actual raised rim or lip of a fitting, many flanged plumbing fittings are themselves known as 'flanges':

Common flanges used in plumbing are the Surrey Although flange generally refers to the actual raised rim or lip of a fitting, many flanged plumbing fittings are themselves known as 'flanges':or Danzey flange, York flange, Sussex flange and Essex flange. Surrey and York flanges fit to the top of the hot water tank allowing all the water to be taken without disturbance to the tank. They are often used to ensure an even flow of water to power showers. An Essex flange requires a hole to be drilled in the side of the tank. There is also a Warix flange which is the same as a York flange but the shower output is on the top of the flange and the vent on the side. The York and Warix flange have female adapters so that they fit onto a male tank, whereas the Surrey flange connects to a female tank.

Chemical reactions

2008-01-29T02:38:00.000-08:00

The oxidation of iron metal

When in contact with water and oxygen iron will rust. If salt is present, for example, in salt water, the iron will rust more quickly. Iron metal is relatively unaffected by pure water or by dry oxygen. As with other metals, a tightly adhering oxide coating, a passivation layer, protects the bulk iron from further oxidation. Thus, the conversion of the passivating iron oxide layer to rust results from the combined action of two agents, usually oxygen and water. Other degrading solutions are sulfur dioxide in water and carbon dioxide in water. Under these corrosive conditions, iron(III) species are formed. Unlike iron(II) oxides, iron(III) oxides are not passivating because these materials do not adhere to the bulk metal. As these iron(III) compounds form and flake off from the surface, fresh iron is exposed, and the corrosion process continues until all of the iron(0) is either consumed or all of the oxygen, water, carbon dioxide, or sulfur dioxide in the system are removed or consumed

Chemical reactions associated with rusting

The rusting of iron is an electrochemical process that begins with the transfer of electrons from iron to oxygen.^[3] The rate of corrosion is affected by water and accelerated by electrolytes, as illustrated by the effects of road salt (calcium chloride) on the corrosion of automobiles. The key reaction is the reduction of oxygen:

O₂ + 4 e^- + 2 H₂O → 4 OH^-

Because it forms hydroxide ions, this process is strongly affected by the presence of acid. Indeed, the corrosion of most metals by oxygen is accelerated at low pH. Providing the electrons for the above reaction is the oxidation of iron that may be described as follows:

Fe → Fe²⁺ + 2 e⁻

The following redox reaction also occurs in the presence of water and is crucial to the formation of rust:

2 Fe²⁺ + 0.5 O₂ → 2 Fe³⁺ + O²⁻

Additionally, the following multistep acid-base reactions affect the course of rust formation:

Fe²⁺ + 2 H₂O ⇌ Fe(OH)₂ + 2 H⁺

Fe³⁺ + 3 H₂O ⇌ 2 Fe(OH)₃ + 3 H⁺

as do the following dehydration equilibria:

Fe(OH)₂ ⇌ FeO + H₂O

Fe(OH)₃ ⇌ FeO(OH) + H₂O

2 FeO(OH) ⇌ Fe₂O₃ + H₂O

From the above equations, it is also seen that the corrosion products are dictated by the availability of water and oxygen. With limited dissolved oxygen, iron(II)-containing materials are favoured, including FeO and black lodestone (Fe₃O₄). High oxygen concentrations favour ferric materials with the nominal formulae Fe(OH)_3-xO_x/2. The nature of rust changes with time, reflecting the slow rates of the reactions of solids. Furthermore, these complex processes are affected by the presence of other ions, such as Ca²⁺, which both serve as an electrolyte, and thus accelerate rust formation, or combine with the hydroxides and oxides of iron to precipitate a variety of Ca-Fe-O-OH species.

Rust prevention

Rust is permeable to air and water, therefore the interior iron continues to corrode. Rust prevention thus requires coatings that preclude rust formation. Stainless steel forms a passivation layer of chromium(III) oxide. Similar passivation behavior occurs with magnesium, copper, titanium, and zinc.

An important approach to rust prevention entails galvanization, which typically consists of coating zinc by either hot-dip galvanizing or electroplating. Zinc is traditionally used because it is cheap and adheres well to steel. In more corrosive environments (such as salt water) cadmium is preferred. Galvanization often fails at seams, holes, and joints, where the coating is pierced. In these cases the coating provides cathodic protection to metal, where it acts as a galvanic anode rusting in preference. More modern coatings add aluminium to the coating as zinc-alume, aluminium will migrate to cover scratches and thus provide protection for longer. These approaches rely on the aluminium and zinc oxides protecting the once-scratched surface rather than oxidizing as a sacrificial anode.

Several other methods are available to control corrosion and prevent the formation of rust, colloquially termed rustproofing:

Cathodic protection makes the iron a cathode in a battery formed whenever water contacts the iron and also a sacrificial anode made from something with a more negative electrode potential, commonly zinc or magnesium. The electrode alone does not react in water but only provides electrons that are otherwise provided by the iron.

Bluing is a technique that can provide limited resistance to rusting for small steel items, such as firearms; for it to be successful, water-displacing oil is rubbed onto the blued steel.

Rust formation can be controlled with coatings, such as paint, that isolate the iron from the environment. Large structures with enclosed box sections, such as ships and modern automobiles, often have a wax-based product (technically a "slushing oil") injected into these sections. Such treatments also contain rust inhibitors. Covering steel with concrete provides protection to steel by the high pH environment at the steel-concrete interface.

Rust

2008-01-29T02:36:00.000-08:00

Rust is a general term for a series of iron oxides formed by the reaction of iron with oxygen in the presence of water. Several forms of rust are distinguishable visually and by spectroscopy, and form under different circumstances.^[1] Rust consists of hydrated iron(III) oxides Fe₂O₃·nH₂O, iron(III) oxide-hydroxide (FeO(OH), Fe(OH)₃. Rusting is the common term for corrosion of iron and its alloys, such as steel. Other metals undergo equivalent corrosion, but the resulting oxides are not commonly called rust. Given sufficient time, oxygen, and water, any iron mass eventually converts entirely to rust and disintegrates. The corrosion of aluminium is extremely slow because the resulting aluminium oxide forms a conformal coating, which protects the remaining aluminium a process known as passivation.

Synthesis of Polyester

2008-01-29T02:24:00.000-08:00

Synthesis of polyesters is generally achieved by a polycondensation reaction. See "condensation reactions in polymer chemistry". The General equation for the reaction of a diol with a diacid is : (n+1) R(OH)₂ + n R´(COOH)₂ ---> HO[ROOCR´COO]_nROH + 2n H₂O

Azeotrope esterification

In this classical method, an alcohol and a carboxylic acid react to form a carboxylic ester. To assemble a polymer, the water formed by the reaction must be continually removed by azeotrope distillation.

Alcoholic transesterification

O \\ C - OCH₃ + OH[Oligomer2] / [Oligomer1]		O \\ C - O[Oligomer2] + CH₃OH / [Oligomer1]
(ester-terminated oligomer + alcohol-terminated oligomer)		(larger oligomer + methanol)

Acylation (HCl method)

The acid begins as an acid chloride, and thus the polycondensation proceeds with emission of hydrochloric acid (HCl) instead of water. This method can be carried out in solution or as an enamel.

Silyl method

In this variant of the HCl method, the carboxylic acid chloride is converted with the trimethyl silyl ether of the alcohol component; trimethyl silyl chloride is produced

Acetate method (esterification)

Silyl acetate method

Ring-opening Polymerization

Aliphatic polyesters can be assembled from lactones under very mild conditions, catalyzed anionically, cationically or metallorganically.

Applications of Polyester

2008-01-29T02:22:00.000-08:00

Polyester is the most widely used manufactured fiber in the United States. Woven polyester fabrics are used for apparel and home furnishings. These include bed sheets, bedspreads, curtains and draperies. Polyester fiberfill is also used to stuff pillows, comforters and cushion padding.

Polyester fabrics sometimes have a "less natural" feel when compared to similarly woven fabrics made from natural fibers, e.g., cotton. However, polyester fabrics may exhibit other advantages over natural fabrics, e.g., improved wrinkle resistance. As a result, polyester fibers are often spun together with natural fibers, e.g., cotton, to produce a cloth with blended properties.

Polyesters are also used to make bottles, films, tarpaulin, liquid crystal displays, holograms, filters, dielectric film for capacitors, film insulation for wire and insulating tapes.

Liquid crystalline polyesters are among the first industrially used liquid crystalline polymers. In general they have extremely good mechanical properties and are extremely heat resistant. For that reason, they can be used as an abradable seal in jet engines.

Thermosetting polyester resins are generally copolymers of unsaturated polyesters with styrene. The unsaturation in the polyester is generally governed by maleic acid or fumaric acid. Another important family is the group of vinyl esters. Here the unsaturation is found in the alcohol part of the polyester. The double bond of the unsaturated polyester reacts with styrene resulting in a 3-D crosslinked structure, the thermoset material. The cross-linking is initiated through an exothermic reaction involving an organic peroxide, such as methyl ethyl ketone peroxide or benzoyl peroxide. Unsaturated polyesters are commonly used as casting materials, fiberglass laminating resins, and non-metallic auto-body fillers. Fiberglass reinforced unsaturated polyesters find wide application in bodies of yachts and as body parts of cars.

Polyester is also widely used as a finish on high-quality wooden products like guitars, pianos and vehicle/yacht interiors (Burns Guitars, Rolls Royce and Sunseeker are examples of companies that use polyester on their products). The thixotropic properties of the sprayable form of polyester make it ideal for use on open grain timbers as it can quickly fill the grain and has a high build film thickness per coat. The cured polyester can then be sanded and polished to a high-gloss, durable finish.

Polyester

2008-01-29T02:20:00.000-08:00

Polyester (aka Terylene) is a category of polymers which contain the ester functional group in their main chain. Although there are many forms of polyesters, the term "polyester" is most commonly used to refer to polyethylene terephthalate (PET). Other forms of polyester include naturally occurring cutin of plant cuticles as well as synthetic polyesters such as polycarbonate and polybutyrate.

Polyester may be produced in numerous forms. For example, polyester as a thermoplastic may be heated and processed into different forms, e.g., fibers, sheets, and three-dimensional shapes. While combustible at high temperatures, polyester tends to shrink away from flames and often self-extinguishes.

Design tool

2008-01-29T02:19:00.000-08:00

The simple box with tote tray can be effective, but becomes less so as more tools are added. The tote tray helps in organizing, and some totes have dividers for segregating small tools. Some toolboxes even have compartments built into the lid for storing supplies such as nails and screws. Yet many tools still must be stored in the compartment below the tote. The large volume of space in this compartment makes this type of box easy to overfill, in terms of both weight and clutter. In addition to the trouble of finding things, there is a risk of heavier items damaging more delicate ones as the toolbox is moved around.

Hence the advantage of tool chests with drawers: heavy pliers and wrenches, for example, can be segregated from the magnifying lens and multimeter. Unfortunately, adding drawers adds weight. Tool chests with three or more drawers may be only semi-portable because of their weight when full. Some may not even have a carrying handle and may be intended to sit atop a rollaround tool cabinet.

Alternatives to Toolboxes

2008-01-29T02:17:00.000-08:00

Toolsets: These are molded plastic cases typically containing a variety of household or automotive tools. Each item snaps into a designated spot in the case, which makes organizing tools much easier than with a conventional toolbox. They are very compact, lightweight, and inexpensive relative to purchasing tools and a toolbox separately. There are two major disadvantages: no ability to customize the selection of tools (sometimes the tools are of lower quality than what one might purchase individually); and little or no space to add new tools and supplies. Thus one still might need a toolbox in addition to the toolset.

Toolbelts and aprons: Though at the far extreme of portability, they are insufficient for storing a large number of tools. One might use a toolbox for permanent storage and a toolbelt or apron to take just what is needed for a job.

Bucket organizers: These consist of rugged fabric or polyester bags draped into and around a 5 gallon bucket. They are lightweight, inexpensive, and can rival the toolbox as a means of storing and moving tools to a job site. Their dozens of pockets permit better organization, yet nearly everything is visible at first glance. That, however, could be a disadvantage as well, since one may have privacy or security concerns if the bucket has to be left in a public area. (By contrast, toolboxes are often lockable and, obviously, opaque). In a vehicle, the bucket may be jostled into spilling some of its contents. Tools left outdoors are better protected in a toolbox. For many purposes, however, a bucket organizer may be preferable to a toolbox. Before purchasing a bucket organizer, note that the bucket itself usually is not included.

Material of Metal boxes

2008-01-29T01:53:00.000-08:00

Metal toolboxes (typically steel) weigh more than plastic ones. A plastic toolbox laden with tools can weigh the same that a comparable steel box does when empty. Metal boxes are also subject to rusting and their sharp edges can mark the surfaces of things they are banged against. Metal is, however, known for being stronger than plastic, so one should balance its disadvantages against the need to withstand abuse and support the weight of many tools.

Types of Toolboxes

2008-01-29T01:50:00.000-08:00

Modern toolboxes are predominantly metal or plastic. Wooden boxes built today are primarily intended for specialized craftsmanship, as machinist, tool an die makers, jewelers and other craftsmen. Many wooden toolboxes were created in the early 1800s but were discontinued in the last 20 years. A modern carpenters' toolbox is composed of a base, a pivotally-mounted top cover, and usually a rack-mounted inside for convenient access. The stereotypical toolbox is usually red in color. Many toolboxes, and chests from a variety of trades can be seen at the Smithsonian Museum of American History

ToolBoxes commonly a hinged cover for a top with a handle for carrying, and one or more latches securing the cover to the box. Open smaller compartments are typically located inside, but larger toolboxes will often have a removable tote tray sitting on a flange inside the lip of the box, with a single larger compartment below.

ToolChests commonly use slide out drawers in lieu of the voluminous open space of the previously mentioned design. It is less common for these Tool storage containers to have a tote tray, although they typically have a hinged top chest storage compartment. Tool chests are primarily made of metal, though some expensive models are made of hardwoods. Often they are sold as a set of a rolling bottom chest with a second, stepped in chest resting above. (Top Chest) Although Tool Chests are designed typically with wheels they are not considered portable because of their massive weight and size

ToolCarts commonly used in the transportation industry for maintenance and repair of vehicles on location. Used as portable work stations, some of the larger types are self powered and propelled as example in automotive racing Pit Carts.

Endmill

2008-01-29T01:26:00.000-08:00

An endmill is a shank-type Milling cutter, a cutting tool used in industrial milling applications. It is distinguished from the drill bit, in its application, geometry, and manufacture. Whereas a drill bit can only cut in the axial direction, a milling bit can generally cut in all directions, though some cannot cut axially.

Types

Several broad categories of end- and face-milling tools exist, such as center-cutting versus non-center-cutting (whether the mill can take plunging cuts); and categorization by number of flutes; by helix angle; by material; and by coating material. Each category may be further divided by specific application and special geometry.

It is becoming increasingly common for traditional solid endmills to be replaced by more cost-effective inserted cutting tools (which, though more expensive initially, reduce tool-change times and allow for the easy replacement of worn or broken cutting edges rather than the entire tool).

Endmills are sold in both imperial and metric shank and cutting diameters. In the USA, metric is readily available, but not commonly used by machine shops; in Canada, due to the country's proximity to the US, much the same is true. In Asia and Europe, while imperial is readily available, metric diameters are standard.

Broach

2008-01-29T01:25:00.000-08:00

Broach (metalwork) A metalworking tool with a series of chisel points mounted on one piece of steel.
Broach (sailing) A sudden instability in the heading of a sailboat when sailing downwind.
Broach (submarine) Submarines operating submerged are said to have broached the surface when a portion of the ship (such as the sail, bow, or screw) other than a mast or antenna comes out of the water. This is similar in intent, if not in 3-D direction, to the use of broach to describe instability in heading of a sailing ship.
BROACH warhead
Brooch (or broach): Decorative item designed to be attached to garments.
Bharuch (also known as Broach): A district in south Gujarat state in India.

types of cutting tools

2008-01-29T01:21:00.000-08:00

A sampling of several types of cutting tools.

Broach
Endmill
Reamer
Drill bit
Tool bit (used in a lathe, flycutter, shaper or planer)
Countersink
Diamond Blade
Diamond tools
Turning Tools

cutting tool

2008-01-29T01:14:00.000-08:00

In the context of metalworking, a cutting tool, is any tool that is used to remove metal from the workpiece by means of shear deformation. It frequently refers to as a tool bit. In order to perform a long time, cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal cutting process. Also, the tool must have a specific geometry, designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on the surface of the piece part surface. The angle of the cutting face is also important as is the flute width, tool margin and tool material.