THIS WEEK IN PRODUCTION TECH: Adhesive Bonding Units, Welding Enclosures and More
Staff posted on April 13, 2016 |

Vulcan Adhesive Debonding Unit from Chief

The patent-pending Chief Vulcan Adhesive Debonding Unit (ADU) is specifically designed to break the bond of structural adhesives in automotive applications.

The Vulcan ADU uses infrared radiation technology to quickly heat the surface to a temperature where the first layer of glue underneath releases cleanly, in as little as 20 seconds. With the adhesive bonds broken, the technician can then separate the materials with less risk of damage to either piece.

The epoxy remains smooth and hard, not sticky, leaving behind a clean work surface. The Vulcan ADU can be used on any vehicle surface, including aluminum, carbon fiber and steel.

Applying heat is a proven method for releasing adhesives, but tight temperature control is needed to not overheat high-strength steels. Aluminum is more challenging because it dissipates heat very quickly and requires a lot of input energy – more than what is found in traditional induction heaters or heat guns.

The Vulcan ADU uses very short waves of infrared radiation to quickly produce up to 600° of heat concentrated at the surface of the material being treated. Even though the unit produces very high output temperature, the lamp's handles and sides remain cool to the touch for safe operation and prolonged lamp life.

The Vulcan ADU has three modes of operation.

  1. Manual: Pulling the trigger will produce whatever level of power the technician set until the trigger is released.
  2. Automatic: The technician sets both a set point temperature and the power level, and the unit will control to that level while the trigger is pressed.
  3. Programmable: The technician can set up to five steps including a specific temperature and how long the Vulcan should stay at that temperature.

To learn more about the Chief Vulcan Adhesive Debonding Unit, visit chiefautomotive.com.

Flexible Welding Enclosures from Huntingdon Fusion Techniques

When welding titanium, zirconium and some stainless steel joints it is important that the welding zone is purged of oxygen to a level as low as 10 parts per million (ppm). 

A flexible chamber is available from Huntingdon Fusion Techniques HFT® for a fraction of the cost of a rigid welding chamber. Flexible Welding Enclosures® provide a solution where a rigid chamber may not be economically viable or where space may be at a premium. 

Luke Keane, Technical Support at HFT® said: “For many years the enormous cost of a metal enclosure prevented all but the major companies taking on work involving the fabrication of these metals. To the rescue came HFT® a decade or so ago with the introduction of these flexible welding bubbles.”

Size for size, HFT®’s range of Flexible Welding Enclosures® can cost less than one tenth of a metal glove box and less than one hundredth of a vacuum system. These enclosures provide a very fast purging time down to a few ppm of oxygen and are ideal for small production quantities of items that need total gas coverage.

Aerospace, automotive, biochemical, medical, food, beverage, semiconductor and nuclear sectors have all taken advantage of the low cost and easy to use Flexible Welding Enclosures®. More recently, companies experimenting with wire plus arc additive manufacturing (WAAM) have also invested in these enclosures.

The standard enclosures are manufactured with two sets of glove ports as standard and the upper half of the enclosure, above the arm entries is optically clear, providing excellent welding vision. A transfer sleeve makes it possible to pass small parts in or out of the enclosure without affecting the purge quality. 

As in the case of the robot manufacturing cells and for laser and arc additive manufacturing applications, special enclosures are designed and manufactured to suit.

Operator comfort and ease of use with Argweld® Flexible Welding Enclosures® versus the disagreeable conditions with a rigid plastic or metal chambers make the HFT® versions a big hit with welding personnel.

Huntingdon Fusion Techniques HFT® have a worldwide Exclusive Distributor network, which can be found atwww.huntingdonfusion.com.

CoroCut QD Inserts from Sandvik Coromant

CoroCut QD dedicated parting off and deep grooving tools are now available in smaller insert widths with internal high-pressure coolant to help customers realize production efficiency.

Considered a “hidden machining cost,” component material waste is an often-overlooked production expense. Wider insert blades cut away more material than necessary during each parting off operation with the excess material ending up in the chip bin.

Using a thinner insert blade not only wastes less material but also allows for more parts per bar when parting off using a bar feeder. Realizing this material savings is especially important for those who machine components made of expensive materials, such as heat resistant super alloys (HRSAs) like Inconel, titanium and cobalt chrome. When working with these high-priced materials in higher volumes, using a thicker insert blade can be costly.

For smaller insert widths, insert handling is easily accomplished with the use of the insert cam key.

Accompanied with each CoroCut QD, the cam key allows the user to leave the finger of the blade in the open position allowing for use of both hands for insert positioning. With the turn of the cam key, the new insert clamp design offers improved rigidity for process security.

CoroCut QD toolholders are made using the same improved tool steel as the larger width CoroCut QD, resulting in 12 percent higher tensile strength.

According to Staffan Lundström, Parting and Grooving Product Specialist at Sandvik Coromant, “As the only product currently on the market that offers over and under coolant in a tool this thin, the CoroCut QD inserts in 0.04”, 0.05” and 0.06” work well for deeper cuts and larger diameters and for all materials, especially HRSAs.”

Parting and Grooving Specialist Scott Lewis adds, “Shops that solely focus on tool costs can be missing the big picture. When a tool costs you more in material waste over time, especially expensive materials, the overall cost to machine a component can be much higher than expected.”

For more information, visit www.sandvik.coromant.com.

Jabro-HFM JHF980 with 4- and 5-flute options from Seco

Seco has recently applied their latest design and grinding developments to increase the number of flutes on the JHF980, allowing it to provide double the feed rate capability of previous Jabro end mills.

Test results indicate the JHF980 4- and 5- flute cutters also offer increased tool life over earlier designs when applied at the same table feed rates.

High-feed machining pairs shallow axial depths of cut with accelerated table feed rates for increased metal removal. Cutting forces are directed axially into the spindle, thereby stabilising the operation, minimising vibration and lessening wear on the machine tool.

JHF980 end mills feature an ultrafine carbide grade and a monolayer TiAIN coating, which contributes to their success in high-feed applications. The coating also helps lower operating costs by eliminating the need for coolant in high-temperature situations. The TiAIN layer insulates the cutters and transfers heat into the chips. 

Cutting diameters for the 4-flute JHF980 range from 2mm to 6mm, while the 5-flute version spans 8mm to 12mm. Both cutters are available in 1.5xD, 5xD and 7xD lengths.

JHF980 cutters cover a wide application area that involves processing a variety of parts from steel to exotic metals. Part examples include casing pockets, knee caps and 3D cavities. The cutters also reduce production costs when processing shallow and deep pockets.

Optimal application of the JHF980 cutters is dependent on several factors, from the age of the machine tool being used to the part size being cut.

For example, the cutters can run at maximum feed rates when applied alongside a highly rigid, modern machine tool. Proper programming is also important to ensure optimisation of the cutter path. With the right CAM program, it is possible for the JHF980 to perform Z level finishes on the sides of a part.

For more information on the Jabro-HFM JHF980 solid-carbide end mill, visit www.secotools.com.

Titex DB133 Supreme Drills from Walter

Walter has recently introduced the Walter Titex DB133 Supreme, a solid carbide micro drill that delivers tight tolerances, high quality surface finishes, superior process reliability, and longer tool life.

The difference for the DB133 Supreme begins with the use of grades WJ30EL and WJ30ER, developed by Walter specifically for micro drills. These grades provide the drills with superior wear resistance.

ln addition, Walter’s new cutting edge geometry increases the process reliability of these new drills and optimized dimensions allow for maximum stability, even with the smallest drills.

The uniform finish on the drill cutting edge and tight tolerances ensures greater workpiece surface finishes. With the Walter Titex DB133 Supreme special geometry, chip removal is effective, even without through coolant. This allows hole depths of up to 8xD to be achieved.

The new solid carbide micro drills, with their 140°-point geometry, can be used universally on many different materials in ISO material groups P, K and N.

Diameters range from 0.02” to 0.12” (0.5 to 2.95 mm). This new drill design is ideal for users in general machining, mold and die making, the energy and automotive industries and any other areas where small diameter, deep holes, are required.

For more information, visit www.walter-tools.com

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