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Why Are The Machined Components Important from Industry Perspective?

Why Are The Machined Components Important from Industry Perspective?

Subtractive manufacturing refers to the processes of machining parts by removing material. Machined components are cutting a piece of raw material to fit specific measurements. The final shape, size, or design is achieved by removing material.

Defining machined parts:

Machined parts are items that we use daily. We rely on them. They range in complexity from simple to intricate designs and are used as spare parts or tooling surfaces. Then, custom machined parts must be factory-made quickly, cost-effectively, and technique-adequate.

 

Is it possible to do the machining of plastics?

In general, industries focuses on machining metal item. But with polymer, machining is also possible. It is a bit tricky, and it needs a lot of expertise. Petron Thermoplast can do this job efficiently.

How can the compatibility of lubricants and plastic parts be determined?

  • Manufacturers monitor alterations in the physical properties of the plastic material under conditions of speed, load, and environment to ensure lubricant compatibility with plastics. Weight, volume, hardness, strength, and elongation are examples of these properties.
  • The manufacturer determines the maximum allowable charge, typically 7% to 10%. When evaluating these tests, make sure they reflect your worst-case scenario.
  • Both lubricants and plastic materials are more prone to change in high temperatures and harsh environments, especially when subjected to high dynamic loads.
  • Using an incompatible lubricant on plastic parts can cause stress cracking, discolouration, and loss of dimensional stability or structural integrity.

How should a lubricant for plastic parts be chosen?

There are mainly three main criteria to consider when selecting a lubricant for plastic parts.

  • Chemistry:

The chemical structure of a lubricant determines its compatibility with plastic. Esters and polyglycols are generally incompatible with plastic, though there are some exceptions depending on the type of plastic. Silicone, mineral oils, perfluorinated PFAE, and synthetic hydrocarbons (SHC or PAO) lubricants typically work well with plastics.

Sometimes additives can cause an unintended or undesirable reaction between the lubricant and the plastic. Solid additives like graphite and molybdenum disulfide can penetrate and weaken a plastic part. On the other hand, PTFE solid additives can be useful in some situations, such as providing dry lubrication or reducing startup friction.

  • Viscosity:

Oils with a high viscosity index (ISO VG of 100 or higher) are less likely to penetrate, crack, or otherwise harm plastic materials. Lighter loads necessitate lower viscosity oils to avoid viscous drag. Higher loads necessitate higher viscosity oils to maintain a lubricant film from start to finish.

In the case of greases, NLGI 1 or 0 consistency aids in the reduction of friction and grease-induced noise (grease slap).

  • Resistance to ageing:

As plastic parts age, lubricants become more likely to attack them. As a result, synthetic lubricants with high ageing resistance are the best option for long-term applications.

Plastic outgassing byproducts, particularly formaldehyde and styrene, accelerate lubricant ageing and should be avoided.

Why are machine plastics used?

Moulding tools and forming equipment used in the various plastic moulding processes are almost always one-of-a-kinds handcrafted creations. They can provide weeks or months to manufacture, resulting in a high cost. When a plastic component is specified and the numbers to be used are small, machining the component becomes more cost-effective. Machines cannot be used on all plastics. The easier it is to machine a plastic, the more rigid it is. Plastics that are more flexible and softer are not suitable for machining.

 

What are the most important considerations when machining plastics?

  • Cutting Tools used in all machining materials rely on the rigidity of the cut component. 
  • When it comes to cutting metals, the natural rigidity of the materials is excellent. As a result, when the cutter (saw, drill, or machine bit) cuts the metal, the component resists distortion. 
  • In the case of plastics, machining lends itself better to rigid materials with good relative stiffness, such as fibre-reinforced thermosetting plastics, glass-reinforced nylons, acrylic, or PEEK. When the cutter attempts to cut the component, less rigid plastic tends to deform and bend away, making fine dimensional tolerances difficult.

 

What are The advantages of machining plastics?

There are several advantages of machining plastics. A few are below.

  • There are no mould costs.
  • Capability to manufacture plastic components promptly,
  • Capability to manufacture in small quantities at a low cost,
  • Can run a design through its paces before committing to tooling,
  • Thicker wall sections are possible.
  • Industry can use machined plastic to make components that are too large to be moulded.
  • The forces needed to machine plastics are minimal.
  • Plastics are typically machine dried.
  • Swarf can be recycled and used again in the compounding process.

 

What are the major considerations for plastic material machining?

Because of the softer plastic machined components, holding jigs and fixtures must be designed with jaws that protect the plastic being machined, which can be made of other plastics shaped to the block’s shape.

Furthermore, the jigs must be strong enough to support the cut material.

Plastics Made of Thermoplastics Machined materials can be cooled with an air blast as long as the resulting swarf is continuous and not chipping. You can cool thermosetting plastics with a liquid coolant, but with plastics prone to swelling in water. Therefore, operators must ensure that machined dimensions do not change.

 

Plastics material machining methods:

  • CNC Machining: If the cut component has a complex shape, the profile can be programmed into a computer. As seen on CNC machines, multiple interchangeable cutters allow for the machining of complex and varied components. People can use a CNC machining centre to produce duplicate quantities of components.
  • Turning: If the desired shape is round, a simple turning operation can be used. Specialist auxiliary equipment attached to the lathe can increase the lathe’s operational capabilities.
  • Sawing: This machining method is almost always used to separate plastic material sections from bar stock for further processing by other machining operations.
  • Die-Cutting: In some cases, die-cutting of plastic material can produce a simple component. The procedure can be done manually or automatically with the help of a special machine. The process is only applicable to the sheet material.
  • Milling: This machining method ranges from simple to profile and CNC milling. As with lathe work, adding a milling machine or a more complex machine can extend the machine’s capability to make more complex shapes.
  • Punching: Certain shapes can be cut using punching presses made of metal. They are always computer-controlled and have multi-tool bits, just like a CNC machine. This process is only applicable to thinner thermoplastic and thermoset sheets.
  • Water Jet Cutting: This process is used to edge trim fibre reinforced thermosetting components that would be difficult to trim using other methods. The material’s tough reinforcing layers resist trimming with standard knives and cutting equipment. The narrow cutting path and quick progress without dust or chippings are benefits.
  • Separating: Acrylic and laminated sheets can be separated by scoring with a sharp knife and breaking along the scored line.

What are the key steps in the polymer bearing considerations process?

There are several steps to take before deciding on the best one.

The proper bearing material is determined by wear, friction requirements, and load-bearing capacity. Temperature, pressure, and running velocity are all important considerations.

Engineered plastic bearings have the following characteristics and benefits:

 

  • design flexibility, no lubrication required,
  • Lightweight, electrically isolating, and chemically resistant
  • Extremely clean for food service,
  • Temperature resistance to 300 degrees Celsius.

Petron Thermoplast makes great quality polymers. These things are also used in plastic material machining. We provide our machined components at an affordable price to all our customers.

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