Produce manufacture forging machines
The present invention relates to a method for manufacturing speaker bottom yoke, which shortens the manufacturing time, increases production capacity, enhances product quality and beautifies the appearance of the product. This method is especially applicable to the base seat of a speaker. As shown in FIG. The iron bar blank material A is first punched into a bottle shape B. Then the blank material is secondarily punched to expand the head end thereof into a mushroom head shape C. At this time, the iron bar blank material with mushroom head end has almost reached the forging ratio of the material.VIDEO ON THE TOPIC: Zwilling J.A. Henckels Kitchen Knife Forging
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Automation of a Production Line for Flashless Precision Forging
Manufacturing industries employ more than 90 percent of workers. A few weeks of on-the-job training is sufficient for most workers to learn basic machine operations, but a year or more is required to become a highly skilled operator or setter. Overall employment of machine setters, operators, and tenders is projected to decline rapidly over the period as a result of productivity improvements and competition for jobs from abroad.
Those who can operate multiple machines will have the best opportunities for advancement and for gaining jobs with more long-term potential. Education and training. Employers generally prefer workers who have a high school diploma or equivalent for jobs as machine setters, operators, and tenders.
Being able to read, write, and speak English is important. Those interested in this occupation can improve their employment opportunities by completing high school courses in shop and blueprint reading and by gaining a working knowledge of the properties of metals and plastics. A solid math background, including courses in algebra, geometry, trigonometry, and basic statistics, also is useful, along with experience working with computers.
Trainees begin by observing and assisting experienced workers, sometimes in formal training programs or apprenticeships.
Under supervision, they may start as tenders, supplying materials, starting and stopping the machine, or removing finished products from it. Then they advance to the more difficult tasks performed by operators, such as adjusting feed speeds, changing cutting tools, or inspecting a finished product for defects. Eventually, they develop the skills and experience to setup machines and assist newer operators. The complexity of the equipment largely determines the time required to become an operator.
Most operators learn the basic machine operations and functions in a few weeks, but a year or more may be needed to become skilled operators or to advance to the more highly skilled job of setter. Although many operators learn on the job, some community colleges and other educational institutions offer courses and certifications in operating metal and plastics machines.
In addition to providing on-the-job training, some employers send promising machine tenders to classes. Other employers prefer to hire workers who have completed, or currently are enrolled in, a training program.
Setters or technicians often plan the sequence of work, make the first production run, and determine which adjustments need to be made.
As a result, these workers need a thorough knowledge of the machinery and of the products being manufactured. Strong analytical abilities are particularly important for this job. Some companies have formal training programs for operators and setters, which often combine classroom instruction with on-the-job training.
For some positions, such as grinders and rolling or pressing setup workers, formal apprenticeships are available. These programs require hours of classroom training, and hours of on-the-job experience.
Workers complete these programs in about 2 to 4 years, depending upon the program. Other qualifications. As the machinery in manufacturing plants becomes more complex and with changes to shop-floor organization that require more teamwork among employees, employers increasingly look for persons with good communication and interpersonal skills.
Mechanical aptitude, manual dexterity, and experience working with machinery also are helpful. Certification and advancement. Job opportunities and advancement can be enhanced by becoming certified in a particular machining skill.
After taking an approved course and passing a written exam and performance requirement, the worker is issued a credential that signifies competence in a specific machining operation. The Society of Plastics Industry, the national trade association representing plastics manufacturers, also certifies workers in that industry.
Certifications vary greatly depending upon the skill level involved. Both organizations offer multiple levels of operator and setter certifications. Certifications allow operators and setters to switch jobs more easily because they can prove their skills to a potential employer. Advancement for operators usually takes the form of higher pay and a wider range of responsibilities, eventually than can advance to be setup workers. With experience and training they can become multiple-machine operators, or trainees for more highly skilled positions, such as, machinists, tool and die makers, or computer-control programmers.
Some setup workers may advance to supervisory positions. Consider the parts of a toaster, such as the metal or plastic housing or the lever that lowers the toast. In fact, machine operators in the metalworking and plastics industries play a major role in producing most of the consumer products on which we rely daily.
Setup workers prepare the machines prior to production, perform initial test runs producing a part, and may adjust and make minor repairs to the machinery during its operation. Operators and tenders primarily monitor the machinery during its operation; sometimes they load or unload the machine or make minor adjustments to the controls. Many workers both set up and operate equipment.
Because the setup process requires an understanding of the entire production process, setters usually have more training and are more highly skilled than those who simply operate or tend machinery. As new automation simplifies the setup process, however, less skilled workers also are increasingly able to set up machines for operation. Setters, operators, and tenders usually are identified by the type of machine with which they work.
Some examples of specific titles are drilling- and boring-machine toolsetters, milling- and planing-machine tenders, and lathe- and turning-machine tool operators. Job duties usually vary with the size of the firm and the type of machine being operated. Although some workers specialize in one or two types of machinery, many are trained to set up or operate a variety of machines.
Increasing automation allows machine setters to operate multiple machines simultaneously. In addition, newer production techniques, such as team-oriented lean manufacturing, require machine operators to rotate between different machines. Rotating assignments results in more varied work, but also requires workers to have a wider range of skills. Setup workers plan and set up the sequence of operations according to blueprints, layouts, or other instructions. On all machines, including those with computer controls, setup workers respond to problems during operation by adjusting the speed, feed and other variables.
They also choose the proper coolants and lubricants and select the instruments or tools for each operation. Using micrometers, gauges, and other precision measuring instruments, setup workers compare the completed work within the required tolerances. Although there are many different types of metalworking machine tools that require specific knowledge and skills, most operators perform similar tasks. Whether tending grinding machines that remove excess material from the surface of solid piece of metal or presses that extrude molten metal through a die to form wire, operators usually perform simple, repetitive operations that can be learned quickly.
Typically, these workers place metal stock in a machine on which the operating specifications have already been set. They watch one or more machines and make adjustments to the machines based on either reading from computers and gauges or measuring the resulting product. Regardless of the type of machine they operate, machine operators usually depend on more skilled and experienced setup workers for major adjustments when the machines are not functioning properly.
These products are manufactured by various methods, of which injection molding is the most common. The injection-molding machine heats and liquefies a plastic compound and forces it into a mold. After the part has cooled and hardened, the mold opens and the part is released. Many common kitchen products are produced with this method. To produce long parts, such as pipes or window frames, an extruding machine usually is used.
These machines force a plastic compound through a die that contains an opening with the desired shape of the final product. Blow molding is another common plasticsworking technique. Blow-molding machines force hot air into a mold that contains a plastic tube. As the air moves into the mold, the tube is inflated to the shape of the mold, and a plastic container is formed. The familiar 2-liter soft-drink bottles are produced by this method.
Work environment. Nevertheless, many operators require stamina, because they are on their feet much of the day and may do moderately heavy lifting.
Also, these workers operate powerful, high-speed machines that can be dangerous if strict safety rules are not observed. Most operators wear protective equipment, such as safety glasses and earplugs, to protect against flying particles of metal or plastic and against noise from the machines. However, many modern machines are enclosed, minimizing the exposure of workers to noise, dust, and lubricants used during machining.
Other required safety equipment varies by work setting and machine. For example, those in the plastics industry who work near materials that emit dangerous fumes or dust must wear face masks or self-contained breathing apparatus.
Because many metalworking and plastics working shops operate more than one shift daily, some operators work nights and weekends. Earnings for machine operators can vary by size of the company, union status, industry, and skill level and experience of the operator.
Also, temporary employees, who are being hired in greater numbers, usually get paid less than permanently employed workers. For the latest wage information: The above wage data are from the Occupational Employment Statistics OES survey program, unless otherwise noted. For the latest National, State, and local earnings data, visit the following pages:. Overall employment in the various machine setter, operator, and tender occupations is expected to decline rapidly during the projection period.
Employment change. Overall employment in the various machine setter, operator, and tender occupations is expected to decline rapidly by 15 percent from to In general, employment growth of these workers will be affected by technological advances, changing demand for the goods they produce, foreign competition, and the reorganization of production processes.
One of the most important factors influencing employment change in this occupation is the implementation of labor-saving machinery. Many firms are adopting new technologies, such as computer-controlled machine tools and robots in order to improve quality, lower production costs, and remain competitive. Computer-controlled equipment allows operators to tend a greater number of machines simultaneously and often makes setup easier, thereby reducing the amount of time setup workers spend on each machine.
Robots are being used to load and unload parts from machines. The lower-skilled manual machine tool operators and tenders jobs are more likely to be eliminated by these new technologies, because the functions they perform are more easily automated.
The consumption of plastic products has grown as they have been substituted for metal goods in many products in recent years. The process is likely to continue and should result in stronger demand for machine operators in plastics than in metal. Both the plastics and metal industries, however, face stiff foreign competition that is limiting the demand for domestically produced parts. One way in which larger U. Another way domestic manufacturers compete with low-wage foreign competition is by increasing their use of automated systems, which can make manufacturing establishments more competitive by improving their productivity.
However, increased automation also limits employment growth. Job prospects.
Over the centuries, progress has been forged in the blacksmiths fire. Human beings have been manipulating metal, hammering out metal and forging metal across the millenniums. The modern civilization we live in today would not exist if mankind had not learned to shape metal.
As for equipment in its forging plants, Toyota switched from inefficient hammer forging machines to forging rolls, forging presses, and upsetters upset forging machines to achieve production capacity increases. In June , Toyota installed a 2,ton forging press made by Ajax Manufacturing Company of the United States and switched the manufacturing of ring gears from hammer forging to die forging. Furthermore, by the end of that year, Toyota installed two roll forging machines made by National Corporation of the United States, introducing a total of 11 forging machines by the end of Die forging, on the other hand, utilizes multiple forging dies mounted on a single forging press to handle multiple processes.
FORGING: Partners in Precision
There is plenty of attention paid to the high-precision designs of advanced materials and parts developed for critical applications, but even parts that are seemingly ordinary or standard run projects require an exceptional degree of precision in concept, engineering, execution, and operation. The manufacturer — which also has heat-treating, threading, and machining capabilities — is well known for its novel and patented MaxBolt load-indicating fasteners. Maxbolt fasteners are manufactured by inserting highly accurate and durable load-monitoring devices into high quality bolts and studs. Accurate assembly and continuous monitoring during production reduce the potential for premature wear, expensive downtime, and catastrophic joint failure. The system offers a simple and reliable method for accurate joint assembly, and helps to maintain the integrity of the bolted joint. The project continued and evolved into a multi-year collaboration, reviewing existing processes, and developing new targets for safer production and higher output. The California-based press builder has previously implemented the FLST design for manufacturers producing extra-long bolts for fasteners supplied to aerospace programs.
US6487771B1 - Method for manufacturing speaker bottom yoke - Google Patents
High-speed horizontal forging presses are essentially horizontal mechanical presses which ram is moving horizontally and can be used for hot, cold or warm forging processes. Horizontal upsetters presses are another type of horizontal presses designed to upset partially heated slugs. A good high-speed horizontal forging machine is expected to have central lubrication, high tool pressure, sufficient tool length and highly rigid crankshaft. The speed range of the high-speed horizontal presses starts from 35 and can reach up to strokes a minute with 5 workstations. Hot forged pinions, idle gears, sleeves and rings and cold forged shafts are the main components manufactured on these machines.
The industrialization of our economies around the world owes a debt to forging and the men and women who operate forging equipment. Without the ability to forge steel and other metals over the past century and a half, we would not have had the parts needed to manufacture cars, build aircraft, drill for oil, mine for minerals or lay down rail tracks. However, as with any process involving manual labor, automation is changing the game.
Occupation Profile for Forging Machine Setters, Operators, and Tenders, Metal and Plastic
Automation is an important approach to achieving more economical production systems. But most automated production lines are inflexible. Flexibility is an essential topic for manufacturing lines which have high machine costs and whose various products are made on variably combined aggregates such as forging lines for example. With the flashless forging process gearwheels are produced in one forming step with such precision that only final grinding after forging is necessary. All aggregates needed for the complete process chain such as material handling, heating system, forging piece handling, die cooling and lubrication system, forging press, heat treatment and clipping press are inter-connected via a field bus and controlled by decentralised CAN-Buscomponents located directly at the machines.
Forging and Stamping
Forgers weigh options such as repair, rebuild, remanufacture or new equipment when considering options to increase capacity. When forging operations need to expand production to meet increased demand for existing parts or to add new product lines, selecting from the available options to bring new equipment online can be challenging. Ultimately, the decision involves striking a delicate balance between fitting within budget constraints and accepting what can often be very long lead times. Forging machines , by design, are massive pieces of equipment that weigh between 25 and tons and rise 10 to 25 feet above the production floor. Despite the violent nature of the forging process, the equipment is designed and built to last decades and it is not uncommon to find equipment from 50 or more years ago still in use.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: cold forging, warm forging, or hot forging. For the latter two, the metal is heated, usually in a forge. Forging is a very important manufacturing process. Forged part has high physical strength and good tough property.
Its energy level can be conveniently adjusted to allow the improvement of energy consumption. Additionally, it can be easily attached Continuous forging is based on a billet feeder, a furnace,
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Precision forged parts are forged parts where very narrow tolerance can be achieved by following the forging process permanently. We are specialized in the production of precision forged parts weighing between 0. The advantage of precision forged parts is that they can be used mostly in different compounds and without additional mechanical machining. Hot die drop forging is the method in our company — sticks are heated and inserted into the appropriate forging tool.
Forging--metal shaping by plastic deformation--spans a myriad of equipment and techniques. Knowing the various forging operations and the characteristic metal flow each produces is key to understanding forging design. Hammer and Press Forging Generally, forged components are shaped either by a hammer or press. Forging on the hammer is carried out in a succession of die impressions using repeated blows. The quality of the forging, and the economy and productivity of the hammer process depend upon the tooling and the skill of the operator. The advent of programmable hammers has resulted on less operator dependency and improved process consistency.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer often a power hammer or a die. Forging is often classified according to the temperature at which it is performed: cold forging a type of cold working , warm forging, or hot forging a type of hot working. For the latter two, the metal is heated , usually in a forge.