Blanchard grinding, a term synonymous with reliability efficiency, has revolutionized the way industries achieve flat, uniform surfaces on large workpieces. This process is known for its ability to quickly remove material and produce high-quality finishes.
What is Blanchard Grinding?
Blanchard grinding, also known as rotary surface grinding, is a method of removing material from one side of a large piece of metal or other material. The process involves a vertical spindle with grinding wheels mounted on a horizontal table. The table rotates, while the grinding wheel remains stationary, allowing for efficient and uniform removal of material.
How Does it Work?
The key to Blanchard grinding is its rotary action. The workpiece is placed on a rotating magnetic chuck, which holds it in place as the grinding wheel descends, and the grinding wheel can be adjusted to achieve different thicknesses and flatness requirements. This rotary motion ensures even material removal and produces a characteristic cross-hatch or swirl pattern on the surface.
Applications:
Blanchard grinding is versatile and finds applications in various industries, and Nifty Bar can provide Blanchard grinding solutions for the following (and more):
Machine Building Industry
Valve and Gas Plate Industry
Die and Mold Industry
Armor Plate Industry
Advantages of Blanchard Grinding
Speed and Efficiency: Blanchard grinding can remove large amounts of material quickly.
Precision: Achieves high levels of flatness and uniformity, critical for many industrial applications.
Versatility: Suitable for a wide range of materials, including magnetic and non-magnetic materials.
Cost-Effective: The efficiency of the process translates to lower labor costs and faster turnaround times.
Blanchard grinding stands out as a reliable, efficient, and precise method for surface grinding. Its ability to handle large workpieces and deliver consistent results makes it indispensable in various industries. No matter the industry, if it requires flat, uniform surfaces, this method offers a solution that combines speed, accuracy, and cost-effectiveness, which is the power of Blanchard grinding.
In the rapidly evolving field of medical manufacturing, precision and reliability are paramount. Nifty Bar offers a suite of specialized services that cater to the stringent demands of the medical industry. With expertise in Double-Disc grinding, Nifty Bar is an invaluable partner for manufacturers of medical, orthopedic, and dental parts, ensuring high-quality, consistent, and efficient production.
Orthopedic and Dental Plates: Precision Matters
Orthopedic and dental plates are critical components used in surgeries to repair and stabilize bones and teeth. These medical devices require exceptional precision and reliability to ensure patient safety and successful outcomes. Nifty Bar understands the high stakes involved and provides advanced manufacturing solutions to meet these needs.
Orthopedic Plates:
Accuracy and Consistency: Nifty Bar’s precision grinding ensures that orthopedic plates are manufactured to exact specifications, minimizing variability and enhancing the fit and performance of implants.
Material Integrity: Utilizing Double-Disc grinding, Nifty Bar maintains the structural integrity of high-strength materials, ensuring durability and longevity of the plates.
Surface Finish: A superior surface finish is crucial for orthopedic implants to reduce the risk of infection and promote better integration with the body. Nifty Bar’s techniques achieve a smooth, precise finish that meets medical standards.
Dental Plates:
Customization: Dental implants often require bespoke solutions tailored to individual patients. Nifty Bar’s precision capabilities allow for customized production runs with consistent quality.
High Tolerance Levels: Dental plates need to fit perfectly to function correctly. Nifty Bar’s Double-Disc grinding process ensures high tolerance levels, reducing the need for adjustments during surgery.
Enhanced Aesthetics and Functionality: With precise grinding techniques, the dental plates not only perform well but also meet the aesthetic demands of modern dental procedures.
Double-Disc Grinding: The Optimal Choice
Double-Disc grinding stands out as the optimal method for producing orthopedic and dental plates due to several advantages:
Efficiency: This method allows for the simultaneous grinding of two sides of the material, significantly reducing production time and increasing throughput.
Precision: Double-Disc grinding delivers unparalleled accuracy and uniformity, which is crucial for the intricate demands of medical components.
Cost-Effectiveness: By enhancing efficiency and reducing waste, Double-Disc grinding lowers overall production costs, providing economic benefits without compromising quality.
Versatility: This process is adaptable to a variety of materials and thicknesses, making it suitable for the diverse needs of medical manufacturing.
By choosing Nifty Bar, medical manufacturers can be confident in the integrity and effectiveness of their critical components. This ultimately contributes to better patient outcomes and advancing the field of medical technology.
In the realm of metal fabrication and part manufacturing, achieving precision, efficiency, and consistency in finishing processes is crucial. Among the various techniques at the disposal of engineers and manufacturers, Double Disc Grinding stands out as a superior method, particularly for flat surfaces. This grinding process offers numerous benefits, from high production rates to excellent dimensional accuracy, making it a preferred choice in various industries including automotive, aerospace, and general manufacturing.
Exceptional Precision and Consistency
Double Disc Grinding involves the use of two abrasive discs that remove material from both sides of a part simultaneously. This simultaneous action not only speeds up the manufacturing process but also enhances the consistency and uniformity of the part’s thickness. The process can achieve tolerances as tight as 0.0002 inches, which is crucial for high-precision components in critical applications. The consistency of this method helps in reducing the variability found in other grinding methods, leading to higher quality parts and fewer rejections in quality control checks
High Production Efficiency
One of the standout features of Double Disc Grinding is its capability to handle high volumes of parts in a relatively short amount of time. This method is designed for both single-pass and through-feed grinding, making it versatile for different production needs. Through-feed grinding, for example, allows continuous processing of parts, which is ideal for long production runs. The efficiency of Double Disc Grinding is particularly beneficial in industries where time and production volume are critical factors, contributing to faster turnaround times and increased throughput.
Cost-Effectiveness
In addition to the high precision and efficiency it offers, Double Disc Grinding is a cost-effective manufacturing process. The initial setup and tooling costs are quickly offset by the speed and volume at which parts can be processed. Moreover, the durability of the grinding discs and the reduced need for secondary finishing processes make it an economical choice for manufacturers looking to minimize overall production costs. By reducing the cycle time and labor involved in the finishing process, companies can achieve a better return on investment.
Versatility Across Materials
Double Disc Grinding is not limited to a specific type of material, making it a versatile option for manufacturers working with a wide range of metals and composites. Whether it’s steel, aluminum, brass, or another alloy, the process remains effective and efficient. This adaptability extends to different sizes and shapes of materials, although it is especially renowned for its effectiveness with flat and parallel surfaces.
Improved Surface Finishes
The quality of surface finishes achievable with Double Disc Grinding is another significant advantage. The process can produce smooth surfaces that are often ready for use in final assembly without further treatment. This not only saves additional processing time but also ensures that components meet strict surface finish requirements commonly seen in automotive and aerospace applications.
Double Disc Grinding offers a combination of precision, efficiency, and cost-effectiveness that is hard to match with other metal finishing processes. It stands as a cornerstone technique in modern manufacturing, capable of meeting the demanding needs of various industries for high-quality, consistent, and economically viable component production. Embracing this technology can lead to significant competitive advantages, underscoring its importance in today’s manufacturing landscape.
Before (right) and after (left) of Double Disc ground parts by Nifty Bar.
As one of the most widely used manufacturing materials in various industries, steel often encounters processes like welding, machining, and cold working. These techniques introduce internal stresses to the metal. If left unchecked, they can lead to several issues, including distortion and cracking. The solution? Stress relieving — a heat treatment process that enhances steel’s stability and strength.
When steel is heated within a specific temperature range — usually below its lower critical temperature — its crystal lattice changes. Holding the steel at this temperature allows time to redistribute stresses, effectively realigning the structure. Then, slow and controlled cooling locks in the newly achieved stress-free equilibrium. This results in a more balanced, uniform microstructure less prone to distortion, cracking, and other structural anomalies.
This blog will discuss the benefits of stress relieving and the factors to consider when using this technique.
Benefits of Stress Relieving
Stress relieving steel is a critical step in metal manufacturing and processing, offering numerous benefits:
Enhanced Dimensional Stability
Stress relieving enhances steel’s size and shape consistency by minimizing the changes that occur during manufacturing processes like welding or machining. By carefully heating the material within specific temperature ranges and timeframes, stress-relieved steel maintains its intended dimensions and becomes less prone to distortion.
Elevated Mechanical Properties
Steel that has undergone stress relieving exhibits improved mechanical properties. By releasing internal defects and refining the crystal lattice structure, stress relieving enhances the steel’s toughness, ductility, and overall strength.
Minimized Risk of Early Failure
Residual stresses are a ticking time bomb within steel structures. Stress relieving defuses this bomb by reducing internal stresses, making steel less prone to unexpected failures and cracks.
Optimized Machinability
By minimizing internal stresses, the steel becomes more responsive to tools, resulting in enhanced ductility and machining flexibility. This optimizes the manufacturing process, contributing to a component’s prolonged lifespan.
5 Factors To Consider in Stress Relieving
When performing stress relieving, several factors should be considered:
1. Material Composition
The chemical composition of the steel significantly influences its behavior during stress relieving. Different alloying elements can affect the steel’s transformation temperatures, phase changes, and mechanical properties.
2. Processing History
The manufacturing history of steel before stress relieving plays a crucial role. The extent of these prior processes affects the overall strategy. For instance, heavily cold-worked steel may require longer stress-relieving times to ensure complete stress reduction.
3. Temperature
The temperature range for stress relieving is critical. Too low, and the desired stress reduction won’t occur; too high, and the steel’s properties might change significantly. Experts use a combination of phase diagrams, empirical data, and experience to pinpoint the optimal temperature range.
4. Duration
Holding the steel at the chosen temperature is equally important. The duration depends on factors like the thickness of the material, its composition, and the extent of prior processing. Longer times may lead to better stress relaxation, but overexposure may alter some of the material’s properties.
5. Cooling Considerations
The cooling phase of stress relieving must also be controlled. Rapid cooling can reintroduce stresses, negating the benefits of the process. On the other hand, controlled cooling ensures that the redistributed stresses are locked in a balanced state.
Get Top-Notch Steel at Nifty Bars
Nifty Bar offers high-quality stress relieving services! We utilize 40” x 48” x 54” furnaces, which ensures that all stresses are removed from a material, restoring it to perfect flatness and form. In addition, we offer various grinding and precision cutting services for various applications across industries.
Contact us today to learn more about how Nifty Bars can provide superior materials that have undergone stress relieving for optimal results. Elevate your projects with our premium steel solutions.
Torch cutting is a thermal cutting procedure that uses oxygen and fuel gas to create a high-temperature flame. The intense heat generated through this technique effectively melts and tears metal objects. One of its key advantages is its versatility, allowing it to easily handle different materials and thicknesses.
Choosing the right contractor can profoundly impact the quality of the end products and overall business productivity. Here are the essential factors to consider when selecting the ideal service provider:
Key Considerations When Finding a Torch Cutting Partner
The cutting partner a business selects is pivotal in determining its industrial operations’ efficiency, precision, and overall success. The following are several considerations to keep in mind:
Experience and Expertise
A company with a proven track record in providing cutting services has likely encountered and overcome various challenges. This makes them adept at handling even the most complex tasks. Moreover, seasoned professionals have practical knowledge acquired through years of hands-on experience, enabling them to skillfully approach each project.
In contrast, selecting an inexperienced or novice partner poses significant risks. Cutting errors can lead to material wastage, increased production time, and compromised product quality. They may also lack the problem-solving abilities and expertise required to deal with unanticipated issues that may crop up.
Equipment and Technology
High-quality cutters and torches are essential in achieving precise and clean cuts. These advanced tools ensure a smooth and streamlined cutting process, minimizing the risk of errors and producing superior end products. A partner with modern, well-maintained machinery is better poised to handle multiple materials and thicknesses, which provides a seamless experience for their clients.
Materials and Capacity
Each business has unique cutting requirements as they may deal with different materials, such as steel, aluminum, copper, and various alloys. The thickness of these metals can also vary based on the industry and application. So, an adept partner must be versatile and capable of working with a wide spectrum of metals and thicknesses.
Capacity is equally vital because it determines the contractor’s ability to handle the required work volume. They must have the necessary resources, infrastructure, and workforce to efficiently accommodate small-scale and large-scale cutting projects. Requesting samples or references for similar work can provide a clearer picture of their expertise in handling specific materials or project volume.
Safety Standards
A reputable company prioritizes safety in every aspect of its operations. It follows and adheres to industry-specific protocols and regulations, ensuring that all processes are conducted securely and controlled. Well-documented policies and standard operational procedures are the best testaments to this commitment to safety.
Turnaround Time
Businesses must balance the desire for speedy results with the need for uncompromised quality. Rushing through cutting processes can lead to errors, inaccuracies, and subpar outcomes.
A reliable contractor maintains a commitment to precision and accuracy. They ensure that each cut fulfills the requirements and quality standards, even when working under tight deadlines.
Cost and Value
Beyond the initial cost, the efficiency and productivity of a torch cutting partner can significantly impact a business’s bottom line. A highly efficient service provider streamlines the process, minimizes material wastage, and optimizes resource utilization. This reduces production downtime and accelerates project completion, contributing to overall cost-effectiveness.
Nifty Bar: Your Trusted Partner for Your Cutting Needs
At Nifty Bar, we provide a wide array of material-cutting capabilities tailored to meet the diverse needs of our valued customers! Our cutting-edge CNC-controlled technology ensures unparalleled accuracy and efficiency in processing various metals, including steel, aluminum, and other alloys. We also provide manual and semi-automatic saw-cutting options.
Surface grinding is a machining procedure to smooth and finish a workpiece’s flat surfaces. It uses a rotating abrasive wheel that produces a precise and smooth finish. This technique is commonly employed in manufacturing industries to achieve tight tolerances and improve the surface quality of metal, plastic, or other substances.
In this article, we will explore the fundamentals of this grinding method, including its operating principles and various types.
How Surface Grinding Works
Surface grinding utilizes a grinding wheel, a tool with abrasive particles that are adhered to its surface and rotates at high speeds. The workpiece, or processed material, is placed on a magnetic chuck or held down by other means. The wheel spins across the surface, cutting tiny shards with each pass. The abrasive granules also remove particles through cutting, plowing, and rubbing.
The grinding process is carefully controlled to achieve the desired outcome. The rotational speed, depth of cut, and feed rate are regulated to maximize material removal while preventing excessive heat buildup. Coolants are also frequently used to dissipate heat and prolong the life of the machine components. As the process continues, the workpiece’s surface gradually becomes smoother and more uniform.
At Nifty Bar, we employ a 30” x 120” table to accommodate various workpieces, effectively processing larger materials. This sizable table provides enough room to secure the piece, which ensures stability and accuracy throughout the grinding process. Additionally, it guarantees that the final products meet exact specifications.
Types of Surface Grinding
The following methods have their strengths, allowing manufacturers to choose the best technique based on the workpiece material, size, shape, and required finish:
Creep Feed Grinding
Creep feed grinding is distinguished by its deliberate use of slow speeds and deep cuts, allowing it to precisely shape intricate geometries. It minimizes heat generation and prevents workpiece deformation by gradually removing material in layers. This technique is especially valuable when working with elements that are difficult to machine using traditional methods.
Form Grinding
Form grinding relies on specialized grinding wheels that are shaped to replicate the desired profile. It particularly applies to manufacturing components with complex geometries that necessitate precise dimensional accuracy. In addition, it is crucial in the aerospace and medical industries, where items feature intricate designs that demand impeccable precision and surface finish.
Peripheral Grinding
Peripheral grinding is a technique that uses the grinding wheel’s outer edge to smooth and shape the surface. Its material removal efficiency is particularly noteworthy, as it can quickly clear many particles, speeding up the manufacturing process. This procedure is commonly used to achieve flat finishes, making it suitable for producing parallel faces on metals.
Plunge Grinding
Plunge grinding is differentiated by the direct insertion of the grinding wheel into the workpiece, resulting in a more aggressive material removal. This method is widely used to create surface grooves, recesses, and other complex patterns. Plunge grinding also enables the production of precisely sized components by adjusting the depth of cut and the feed rate.
Rotary Grinding
Also called Blanchard grinding, rotary grinding is a unique approach that involves a fixed grinding wheel and a rotating magnetic chuck. It allows for rapid material removal by keeping the wheel stationary and spinning the piece. This configuration is intended to efficiently remove material from large and heavy workpieces.
Through-Feed Grinding
Through-feed grinding is a specialized technique best suited for slender and elongated materials. This method involves feeding the workpiece constantly through the grinding wheels, resulting in consistent debris removal along its length. It finds applications in industries such as automotive and manufacturing, where components like shafts and rods need precise dimensions.
Choose Nifty Bar for Premium Grinding Services
At Nifty Bar, we offer precision grinding services that meet and exceed our customers’ requirements! We utilize cutting-edge processing technology, resulting in the creation of accurate components that adhere to tight tolerances. Whether you require Blanchard, surface, or double-disc grinding, we’ve got you covered!
Waterjet cutting is an advanced technique that uses a high-pressure water stream to achieve precise cuts across diverse materials. The water is pressurized to extremely high levels and then expelled through a nozzle at fast and high velocity. In some cases, abrasives are added to the stream to enhance the cutting capabilities.
There are various waterjet cutting service providers, each with different work styles and quality. Navigating these choices and finding the partner that precisely aligns with your specific requirements can feel overwhelming. Thus, this article will list the factors to consider when selecting the ideal waterjet cutting services company.
Key Considerations When Sourcing Waterjet Cutting Services
Finding the right partner can significantly impact projects overall quality and efficiency. Here are the factors to consider to help you establish a valuable partnership with the most qualified service provider:
Expertise and Industry Knowledge
Experienced service providers have a wealth of knowledge and insights; they have likely encountered various materials and cutting challenges throughout their years of operation. This experience enables them to precisely and efficiently handle unique cutting requirements. They can also offer guidance on the optimal techniques, speeds, and parameters for different materials.
In addition to technical expertise, they are also committed to staying up-to-date with industry trends. They invest in continuous training and education to keep pace with technologies and cutting methods. This ensures that they can offer the most efficient and innovative solutions.
Cutting Technology and Capabilities
When selecting a service provider, it is essential to inquire about the cutting technology and capabilities they offer. First, assess whether they have state-of-the-art machinery and tools. Cutting-edge equipment utilizes advanced features that improve the process. This includes high-pressure pumps that generate the necessary water pressure for optimal cutting performance.
Additionally, inquire about the software and programming capabilities the service provider employs. Modern systems utilize sophisticated apps that allow for precise control over the operation. Advanced software can also handle complex designs and intricate cuts, ensuring accurate replication of even the most intricate patterns and shapes.
Turnaround Time
Timely delivery is often a top priority in any project. It is important to communicate the project timeline and expected deadlines to potential service providers and gauge their ability to meet these requirements. Ask about their production capacity and scheduling capabilities to ensure they can handle your project within the desired timeframe.
Cutting Precision and Tolerance
It is critical to prioritize accuracy and precision, especially for projects requiring tight tolerance levels. You can request samples, references, or client testimonies of their previous works to assess the service providers capabilities. Examining these documents will allow you to evaluate the quality of their cuts and determine if they meet your project requirements.
Industries such as aerospace and automotive often have strict cutting standards and design specifications. Hence, the service provider should have experience working with similar requirements. Inquire about their success in executing projects for these industries or others requiring high precision.
Quality Control
A reputable service provider has robust quality control processes to ensure that each cut meets the required specifications and adheres to industry standards. In addition, certifications such as ISO 9001 indicate their dedication to maintaining high-quality standards. These demonstrate that they have a quality management system and follow standardized practices to consistently deliver quality results.
Cost and Value
While cost is crucial, it should not be the sole determining factor in decision-making. Understand the pricing structures and payment terms offered by different providers. Some may have fixed pricing for specific cuts or material types, while others provide customized quotes based on the project requirements. Assess whether the structure aligns with your budget and the necessary waterjet cutting services.
Partner With Nifty Bar for Precision Cutting Services
At Nifty Bar, we pride ourselves on offering comprehensive material cutting capabilities to meet diverse customer needs! Our services encompass CNC-controlled flame cutting, abrasive waterjet cutting, and manual and semi-automatic saw cutting. We can create part programs from original drawings or customer-supplied DWG or DXF files.
Contact us today to learn more about our precision cutting and manufacturing solutions! You can also request a quote now.
Double Disc grinding simultaneously grinds two sides of material using two opposing abrasive wheels. It is a very effective grinding technique for obtaining surface smoothness, flatness, and parallelism with tight tolerances in the appropriate applications.
This grinding technique can remove more material, cutting the grinding time in half. Additionally, this method can efficiently process various materials — including stainless steel, tool steels, sintered metals, high-strength alloys, ferrous or non-ferrous metals, bronze, copper, aluminum, and more.
What Is Double Disc Grinding?
Double Disc grinding is typically employed for high-productivity manufacturing requirements. However, many factors may affect the output rates, including the size, material, stock removal,starting flatness, and tooling arrangement. Depending on these factors, outputs can be as high as 40,000 parts per hour or just a few pieces.
This technique is very effective and can cut pre-machining costs by as much as 50% since the material is removed from both sides in equal amounts in a single operation. It is ideal for requirements under the following conditions:
The parts have equal surface area requirements on opposing surfaces.
The size of the component required is close to the size of the grinding wheels.
The length, diameter, and overall width should be within tight tolerances.
The part’s thickness should be related to the opposing face to be processed.
Advantages of Double Disc Grinding
Depending upon the material and start flatness high dimensional accuracy can be obtained via Double Disc grinding, with tolerances, parallelism, and flatness down to 0.0005 inches (0.0127 mm). Controlling the thickness of small metal pieces using it is also economical.
Double Disc grinding can also improve your parts manufacturing processes in the following ways:
Reduced Machine Cost
Because the grinding wheels degrade throughout the conventional grinding process, they occasionally need to be changed or redressed. On the other hand, double disc grinding lowers the wear rate, resulting in fewer grinding process redressing stops.
High Degree of Accuracy
The ability to simultaneously grind both sides of the workpiece gives operators more control, allowing them to achieve tighter tolerances for flatness and parallelism checks. Additionally, when grinding aluminum, the method may produce surface polishes as high as 16 Ra and dimensional tolerances of 0.0005 in. Flatness tests can also achieve the same degree of precision.
Internal Stress Relief
Double Disc grinding lessens the workpiece’s residual load due to how it operates. During secondary operations and final machining, stability is improved when residual stress is decreased.
Better Surface Finishes
This technique can attain flatness tolerances that would be extremely challenging to achieve using a single-sided grinding procedure. In addition, Double Disc grinding generates a better surface polish than many other grinding procedures by lowering or removing grind patterns as pieces depart.
Double Disc Grinding With Nifty Bar
Materials processed through double disc grinding can be used to manufacture several products and applications, including the following:
Knives, handles, and clips
Component part blanks
Connecting rods
Cutters and dies
Extrusions
Gages
Gears and gear blanks
Laminations
Medical, dental, and orthopedic plates
Shims, spacers, and washers
Stampings
Substrates
Valve plates
Nifty Bar’s double-disc grinding technology offers precisely controlled processes creating superior surface finishes. We cater even to the most difficult-to-grind materials, such as titanium, Inconel, and a wide array of metal parts. Backed by our team of grinder experts, our mission is to meet our customer’s requirements with precision and quality.
Contact us to book an appointment or to request a quote. We look forward to working with you!
Double-Disc Grinding and Flat Lapping are cost-effective machining processes for components requiring size control or a fine or specific surface finish. Although these methods have identical purposes, their operations, advantages, and disadvantages vary.
Nifty Bar offers Grinding, Cutting, Milling, and Finishing services for parts, tooling, dies and molds, pre-machined blanks, fixtures, and signages used in various industries. Further, our capabilities allow us to deliver Double-Disc Grinding services that satisfy our client’s need for excellent dimensional control.
This article will discuss the differences between double-disc grinding and flat lapping and assess the best option for various applications.
What Is Double-Disc Grinding?
Double-Disc Grinding uses two opposing abrasive wheels to simultaneously grind both sides of a component. The wheels are side-mounted on a pair of spindles facing each other, and — because both sides of the workpiece are ground at the same time — fabricators achieve faster turnaround time. This method can also achieve tight-tolerance surface finishes, flatness, and parallelism in suitable applications.
This method is often classified into two machine types — horizontal and vertical double-disc grinder — based on how the grinding wheels are oriented and how parts cross through them. A double-disc grinder is horizontal if the wheels are paralleled to the floor and vertical if they are perpendicular.
The product of this grinding technique are flat plates with finishes to 16 Ra and parallel tolerances to .0005″, depending upon material type, size and stock removal.
Applications of Double-Disc Grinding
The most common applications for Double-Disc grinding are as follows:
Advantages and Disadvantages of Double-Disc Grinding
Double-Disc grinding ability is to extract equal parts of material from opposite sides of a workpiece that results in applying a reduced amount of internal stress to the materials. Furthermore, it enhances stability during machining operations, leading to higher accuracy and parallelism. Moreover, up to 50% of pre-machining costs are saved since this technique can achieve flatness tolerance faster than single-sided grinding.
On the other hand, Double-Disc Grinding fails to produce surface finishes as smooth as flat lapping. The latter grinding process is often used to correct irregularities or deterioration on the surface of metal parts.
What Is Flat Lapping?
Flat lapping is a mechanical sanding or polishing procedure where an abrasive is placed between two surfaces that are honed together. This process often results in a more accurate surface finish for elements and compounds like cast iron, ceramics, tungsten, plastics, carbon compounds, stainless steel, bronze, rubber, and silicon.
Applications of Flat Lapping
Flat lapping utilizes abrasive grains mixed with either oil- or water-based liquid vehicles to achieve a smooth surface. This method is typically used in the following applications:
Hard and brittle metals
Machining materials (e.g., glass)
Valve manufacturing
Polishing operations (automotive industries)
Advantages and Disadvantages of Flat Lapping
Due to the less complex machining process, flat lapping doesn’t require skilled laborers to complete the procedure, increasing its production rate. This technique also removes burrs on materials to achieve a high surface finish without generating heat.
However, flat lapping is generally slower than double-disc grinding, as only one side of the workpiece is furnished for each cycle. Additionally, it is not as pocket-friendly because it can only remove a minimal amount of stock on the material, and the surface finish needs to be uniform.
Why Choose Nifty Bar
Double-Disc Grinding offers more advantages to consumers than flat lapping. Not only is the former a more practical alternative, but fabricators can achieve a faster turnaround time than the latter.
Nifty Bar delivers Grinding and Cutting solutions with high-precision quality through our services, such as Blanchard Grinding, Double-Disc Grinding, and state-of-the-art Waterjet cutting technologies! Our capabilities and expertise enable us to support product prototyping and part production for the Medical, Architectural, Aircraft, and Automotive Industries just to name a few.
Have you ever seen those commercials for waterjet cutting showing a guy cutting through a metal plate with a jet of water? It’s pretty impressive. But what is Water Jet cutting, and how does it work?
Read on to learn more about how waterjet cutting works and its benefits.
What is Water Jet cutting and how does it work?
Waterjet cutting is a versatile and efficient way to cut various materials. It works by using a high-pressure jet of water, MIXED WITH GARNET, to cut through the material cleanly and precisely. This process can be used for both industrial and personal purposes, and it is an alternative to traditional methods such as sawing, drilling, or milling. Waterjet cutting is quick, easy, and accurate, making it a popular choice for many projects.
The benefits of using a waterjet cutter
There are many benefits of using a waterjet cutter over other methods, such as:
Water Jet cutting can cut through any material.
They can create very intricate cuts and designs.
Waterjet cutting is a very precise method of cutting.
There is no heat-affected zone (HAZ) when using a waterjet cutter. This means that the material being cut will not be damaged by heat.
Waterjet cutting is a clean method of cutting because there is no dust or debris created during the process.
Different types of materials Water Jet cutting Could be used
Waterjet cutting COould be used for a variety of other materials. These include, but are not limited to:
Metals such as aluminum, brass, and steel
Non-metallic materials such as glass, plastic, and stone
Composite materials such as carbon fiber and Kevlar
Each type of material has its unique properties that must be considered when choosing the best waterjet cutting method. For example, metals are strong and durable but can be difficult to cut through due to their hardness. Glass is fragile but can be cut with very high precision.
Waterjet cutting can also be used on composite materials, which are made up of multiple different types of material bonded together. This makes them extremely strong and resistant to damage. However, composite materials can be difficult to cut due to their complex structure.
When choosing a waterjet cutting method, it is crucial to consider the type of material that will be cut as well as the desired outcome. Waterjet cutting is a versatile technology that can be used on various materials. With proper planning and execution, waterjet cutting can produce precise, high-quality results.
Types of cuts using waterjet cutting
Waterjet cutting is a versatile process that can be used to cut various materials. The type of cut made with waterjet cutting depends on the material being cut and the application for which it will be used. Some common types of cuts made with waterjet cutting are:
Straight cuts: Straight cuts are the most basic type of cuts made with waterjet cutting. They are typically used for simple applications such as trimming or shaping edges.
Contour cuts: Contour cuts are more complex than straight cuts and are used when more precise shapes or patterns need to be cut into a material.
Kerf cuts: Kerf cuts are made by directing the jet of water at an angle so that it cuts a V-shaped groove into the material. They are often used for making decorative cuts or for joining two pieces of material together.
Pierce cuts: Pierce cuts are made by starting the cut at an edge of the material and then moving the jet of water in a circle to create a hole in the center of the material. They are typically used for applications such as creating holes for fasteners or making openings for pipes or ductwork.
Nifty Bar Waterjet Cutting Services
Adding speed, precision, and efficiency to your machining projects is a breeze with Nifty Bar Waterjet Cutting. From cutting complex shapes to making quick work of intricate designs, our waterjet cutting services are perfect for various applications.
Nifty Bar Waterjet Cutting can help you achieve the perfect finish on your project, whether you’re working with metals, composites, stone, or glass. Our state-of-the-art waterjet cutting technology can handle even the most challenging cuts with ease.
With Nifty Bar Waterjet Cutting, there’s no need for secondary finishing operations. We can produce parts ready to use right out of the machine. That means you’ll save time and money on your project.
If you’re looking for a way to take your machining projects to the next level, look no further than Nifty Bar Waterjet Cutting. We can help you achieve the perfect finish every time. Contact us today to learn more about our waterjet cutting services. We look forward to working with you!
Understanding the Benefits of Precision Saw Cutting
In precision saw cutting, a mechanized blade cuts through metal, wood, or plastic workpieces to create smaller components or pieces. Precision cutting is typically used to make components — such as pipes, tubes, and bars to the right dimensions. Unlike other cutting processes like laser cutting or waterjet cutting, saw cutting techniques use a sharp, hard blade to physically cut the material. These blades come in a variety of different styles, such as circular saws, cold saws, or band saws, to accommodate different material thicknesses and specifications. Precision sawing offers a wide range of benefits that make it essential in various fabrication projects.
Benefits of Precision Saw Cutting
Precision cutting offers several benefits for both high-volume and low-volume orders. Some of the most common benefits include:
Cost-Effectiveness. Precision sawing is a quick, simple process that doesn’t require specialized tooling and results in little to no material waste. Cutting yield loss is also typically covered in the price so there are no surprises.
Speed. Both manual and CNC sawing equipment can quickly cut through single workpieces for complex custom goods or large batches of pipes and bars. This ensures that products are ready for subsequent operations when you need them.
Outsourced services allow for lean manufacturing operations. By outsourcing your precision saw cutting services, you can save valuable plant floor space for your specialties rather than setting up bulky sawing equipment.
Precision. High-quality sawing processes can cut goods so they meet required specifications within tight tolerances and with minimal waste.
Improved cash flow. Outsourced precision sawing services can fit within your timeline so you don’t pay for unused time, which improves operational cash flow.
Nifty Bar — Your Precision Saw Cutting Specialists
Our saw cutting services use precision plate saws with excellent straightness and squareness capabilities. Because there is no heat-affected zone, saw cutting produces parts without work-hardened edges. Precision saw cut parts can help save set-up and processing time in subsequent operations and are suitable for many types of applications.
Other than saw cutting, we also offer CNC torch cutting, waterjet cutting, and more to create high-quality workpieces and simplify your production project.
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