Tool specifications and categories
Sandpaper : 150#,180#,320#,400#,600#,800#,1000#,1200#.
Golden sandpaper : 0#,2/0,3/0,4/0,5/0,6/0.
Oilstone : P-20 steel without heat treatment with brand GESSWEIN DF, ordinary oil stone roughness 120#,220#,400#,600#.
EDM OILSTONE : Provincial H13 steel has been heat-treated with BORIDE EDM 150#, 180#, 320# roughness.
Felt Reel : Cylindrical,Vertebra,Square Tip.
Drill Plaster : 1# 3# 6# 9# 15# 25# 35# 60#
Color : White Yellow Orange Green Blue Brown Red Purple
File : Square,Round,Flat,Small,Angle and other shapes.
Flint: Shank sizes are ?3/32", ?1/8", ?1/4", ?6mm, ?3mm. Shapes are cylindrical, vertebral or can be made into your desired shape and size with a Flint King.
Diamond Sharpening Needles : 3/32" shanks and 1/8" shanks are available in round, cylindrical, rectangular, and vertebral shapes.
Sandstone boots: with the front and rear pull head and double-sided tape on the boots with the size of two kinds of: 17X28, 8X17.
Copper: ?1/8", ?1/4" shanks into a flat shape in order to facilitate the paste on the sandpaper to save the depth of the bone or plane.
Bamboo sheet: Various shapes are made to fit the operator and the shape of the mold, the function is to press the sandpaper and grind on the mold to achieve the customer's required finish.
Fiber stone: 200# 400# 600# 800#
Color: black, blue, white, red
Mold polishing
1. If the mold is not allowed to have sparkles, the polishers have to look at it clearly or find out the sparkles by different methods and remove them. Because every time after the mold test found that there is a pattern. The mold has to be assembled and disassembled and try the mold again, which will take a lot of working hours and waste materials.
2. Lighting rough male does not need to be more serious than the young male, as long as the copper male surface or enterprise body position protruding things to save the concave does not necessarily have to play smooth, it is best to find out the problem before lightening, the young male we have to play to smooth, all the corners of the body of the enterprise position to save to the clear and smooth, concave as to find out the reasons for the same, do not necessarily have to play smooth.
3. Copper male such as the receipt of the spark machine bronze fixture, the following four reference nails, must be placed on the bottom of the soft objects (such as cloth, cardboard) to prevent unnecessary damage to the workpiece movement, placed on the table or shelf also the same practice.
4. hand or machine to 400 # sandpaper above the attention of the environment around the mold clean, sandpaper should be cut before the sandpaper rolled on each other rubbing the sandpaper on the slightly coarse sand particles to remove, so that will reduce the lightening suddenly hit the coarse grain.
5. If the lighter finds that there is a sudden roughness or has been lightened when the mold remodeling, found that there is an unknown object hit the plane should be reported to the supervisor to know. Another polishing should be completed to notify the supervisor, should not be completed and handed over to the future test mold only to find that the waste of time and trouble.
6. Carbon crystal polishing: Carbon crystal in CNC gong machine processing, depending on the surface roughness, first from 400 # sandpaper to start playing to remove rough lines, and then turn 600 #, 800 #, 1000 #, when there is no grain, you can use gold sandpaper to play the light, but with water together with the play light, and finally available to clean the cloth will be thrown to the smooth surface.
7. Check the spark pattern in the mold, you can first wash the mold, with a sweep evenly coated with copper acid on the surface, about 3 ~ 5 minutes later, wash the mold with water, blow dry with an air gun. After the test, the surface of the molding without sparkling pattern will be darkened, and the surface of the sparkling pattern will show shiny spots. Repeat the process with oil stone or sandpaper until the surface is free of sparkles, and until it is completely darkened by the copper acid test. (The amount of copper acid is 3.5 parts of water and 1 part of copper acid)
Molding polishing (mirror surface)
This is done by pulling the gun back and forth, by rotating the sanding machine and by hand. It depends on the shape of the mold, flat surface, small surface, unevenness and so on.
Example 1: Polished molding size 4 "X6 "X3/4" deep, bottom corner 1/8 "R on all sides, corners 1/4 "R on all sides.
Polishing requirement: #1 S.P.1. Molding hard 48RC~52RC
Machining surface: Spark machined to shape
Start with a hot water wash to clean off the grease stains, then wipe it dry and then wipe it again with fire alcohol until it is dry. . Use front and back head with 150#EDM oil stone, first hit the bottom 1/8R rounded corners and 1/4R bit of the body, and then hit the body to a large plane, hit to no spark pattern, turn 320 oil stone and repeat or use 180# sandpaper with a flat boot to no 150# oil stone pattern, use 320 sandpaper with the previous direction to turn 45o or 90o hit to no coarse
grain, only 320# sandpaper grain, and then turn 400# sandpaper and then turn 90o to no grain, only 320# sandpaper grain, and then turn 320# sandpaper and then hit to no grain. After turning 400# sandpaper and then turn 45o or 90o to hit all 320# grain. Repeat 600#, 800#, 1000#, 1200#, 0#, 2/0, 3/0, 4/0 gold sandpaper, hit to all no grain, to check the four sides of the penguin position, rounded corners of the position, the large plane to be all grain-free.
Begin to use drilling plaster to lighten, first of all, repeat the molding with fire water, alcohol cleaning, depending on the molding of the texture left by how thick and young and what number of drilling plaster, start with 15 # drilling plaster, round rotating sanding machine is best to use the diameter of ?1" large and loose felt reel with the end of the big plane, felt reel body to play the molding body with the diameter of ?3/8" felt reel to play the four sides of the R 1/4" rounded, 1/4" diameter felt reel to play the bottom of the corner, the bottom rounded. diameter felt reels to round the bottom corners.
If the mold has not too much sandpaper grain left, we do not sand too long, mold heat mold will produce orange peel grain or a small number of pinholes to.
Drill plaster should not be too little, the best surface layer into a thin desert, do not felt reel too much direct hit the molding opportunities, put the drill plaster should be put on average, with the felt reel will be coated with diamond plaster average before you can start the grinder, pay attention to the car speed should be slow, can be a little bit of force to pressure to play the light. If the drill plaster is big knot, use drill oil to dilute the drill plaster, only a small amount can be used, such as too much drill oil will fly away the drill plaster felt reel has the opportunity to grind directly to the mold piece also produces orange peel lines and small pinholes.
After playing well, use clean paper towel or cotton valley to wipe a small part of the place, test to see if there is sandpaper pattern, no pattern can be wiped clean with paper, use fire water and wine to wipe clean the molding piece with 3#, 6#, 9# drilling plaster, repeat the above operation, and finally use 1# drilling plaster to wipe the molding piece with cotton by hand gently press to the bright, the molding piece will be completed. Put the mold in a safe place and cover it with paper or cloth to make sure that nothing will fall down and damage the surface of the mold.
Time: Rough polishing ------ Depending on the thickness of the molding, it should take about 20 hours to complete;
Young polishing ------ It takes about 24 hours to polish to a 4/0 grit sandpaper;
Drilling and plastering ------ The whole process of drilling and plastering takes about 1.5 hours;
Total time 45.5 hours.
Example 2: The size of the polished part of the mold: 2 "X2 "X1/8" deep four sides and sharp corners
Processing surface: H13 heat treatment and spark machine
Similar to the operation of Example 1, but the corners of the four edges and the body of the first to hit the flat surface, the best way to use this mold is to use the front and back of the head, with the square nozzle felt reel drilling gypsum.
Time: Rough polishing ------ about 6 hours;
Young polishing ------ about 8 hours;
Throwing diamond plaster ------ about 1 hour;
Total time 15 hours.
Workpiece surface finish standard
#1 Drill Plaster (Optical Requirement)
#3 Drill Plaster Polishing (Mirror)
#6 Drill Plaster Polishing (Mirror)
#15 Drill Plaster Polishing (Mirror)
600 Sandpaper (Gloss)
400 Sandpaper (Gloss)
320 sand paper(glossy)
600 oil stone(matte)
400 oil stone(matte)
320 oil stone(matte)
Spraying #11 coarse glass beads
Spraying #240 sand
Spraying #24 sand
Polishing standard
I. Before the mold test, you must check whether the polishing is completely in line with the requirements or whether it is completely finished.
II. Check whether the spark pattern is correct and whether the mold can be released.
Three. For all mirror polishing, the steel must be ASSAB 136, see Hard 52-54HKC.
The surface finish of the workpiece is according to the following new standards.
SPI-SPE
A-0
A-1
A-2
A-3
B-1
B-2
B-3
C-1
C-2
C-3
D-1
D-2
D-3
1. See hardening methods
- Vacuum heat treatment.
- When hardened, it must be indicated in the heat treatment notice form:
a Desheng 2083ESR
b Hardness 52-54HRC
c High-temperature quenching + 2 times of low-temperature tempering
d Mainland factories can be heat-treated by Desheng; Hong Kong factories can continue to use Holland & Bailey.
2. Machining Methods
Use EDM spark erosion machining, but need to pay attention to the following points:
- Use low current machining. Because high-current roughing is easy to leave a hole, when polishing left deep holes.
- EDM is only applicable to Japan spark machine processing, because Taiwan machine spark pattern depth is not the same, will leave deep holes. In order to see the "holes" only after polishing and drilling plaster, if there are concave holes, you need to start from #320, which will waste a lot of man-hours.
Polishing is a specialized craft, easy to learn and hard to master, but with the right methods and tools, you can still achieve professional level. In order to improve the production efficiency, we need to learn the foreign advanced polishing knowledge and technology, to meet international standards.
The company has several kinds of polishing tools: rotary grinding wheel, front and back reciprocating sanding machine, ultrasonic sanding machine. All polishing team members, team leaders and managers must use mechanical equipment polishing, no longer need to use manual form. Now deep polishing skills backward, the need for comprehensive implementation of mechanical polishing.
According to NOVAPAX experts, several polishing techniques are introduced:
1. Object of polishing: workpieces of 1-2767 HRC 56-60 steel, polishing area of 28 spheres, depth of 20MM.
Degree of polishing: Polishing from the EDM grain (CHARMILL #33) to A-2 mirror surface.
Technique:
A. With a diamond ring, press the diamond ring with pressure.
Turn at maximum speed of 20,000 RPM with a 1mm repeat stroke. Slowly make a circle, clockwise from the outside, then move to the inside after a circle until you reach the center (takes about 2 minutes)
Clean up the workpiece and check to make sure you've cleaned out all the spark patterns. If complete go to "B".
B. Using the brass ring
Apply 15 grams of plaster and lubricant to the workpiece. Lightly press the copper ring to rotate in a circle, move slowly 8MM/SEC. Clockwise to follow the specified route from outside to inside. You can't force the copper ring and cause deep lines.
Save a cleanup after checking whether the workpiece to achieve the effect, not to repeat again. (It takes about 5 minutes)
C. Use plastic ring (PP material)
Place the workpiece with 6" drill paste and lubricant, and repeat the "B" method. Press the ring gently, but do not force the ring. Finish cleaning the workpiece to check the effect, and repeat the process if it is not satisfactory. (It takes about 3 minutes)
D. Use the cloth ring
Adding 3 grams of diamond paste to the workpiece, gently press the cloth ring and repeat the process in "B". When finished, check the finish of the workpiece and repeat the process if it does not meet the requirements. (Takes about 5 minutes)
E. Manual saving with cloth.
The workpiece is polished by adding 1 piece of diamond paste, using method "B" (about 3 minutes)
The whole time is about 30 minutes, including cleaning and changing tools and checking the workpiece.
2. Mirror polishing
If the finished product is flat, then change to square or triangular rings, the same process as "1".
3. Fast polishing (only for clean, not smooth)
10 kinds of diamond plaster (60?, 45?, 15?, 10?, 7?, 5?, 3?, ...) mixed together with a copper ring. Mix them together first with a copper ring, followed by a rubber ring and a cloth ring. The process.
Approximately 15 minutes.
4. Sandpaper reel - for P-20 steel
Sandpaper from coarse to fine (#180? #240? #400? #600? #800?...). The strength is reduced from 25Kg to 0.2Kg. It is quick and easy to remove the knife lines. First use sandpaper reel to remove the knife lines, followed by polishing method with the same copper glue ring.
If the workpiece is too deep or for the divination surface can be swept or carpet reel and other tools instead; under the mold deep bone place can be used repeatedly sanding machine with fixture head oil stone, diamond steel file to lighten.
If the workpiece has been etched with a spark machine mirror 0.8M glossy surface, just use #0 sandpaper or 6? Finally, use 3? drilling, plaster polishing." Do not use force", leading to over-polishing, resulting in "orange peel".
General awareness of polishing
1. When a new mold piece begins to process, it should first be cleaned with kerosene (kerosene) wipe, and then use alcohol to wipe all the oil stains and undesirable things, so that the molds can be refreshing to play the oil stone, the oil stone surface will not stick to the dirt to lose the cutting function.
2. Lighting should be done first for the bottom corner of the mold, the bone pit and the dead corner place, and then for the body and the big plane.
3. Part of the mold is three to four pieces of the clamping buried and composed of a mold, individual mold along the edge of the mouth only to play to the rough pattern or sparkle pattern, after all the mold clamping to play to the smooth, plastic parts when the beer will be slightly smooth clamping position.
4. Large plane or high body position of the mold, must be played to remove the rough pattern after the flat steel and red Dan to check the mold has no unevenness or reverse mouth of the bad situation. If there is any unevenness, the finished product will stick to the mold or drag the flower.
5. The mold is a piece of plane may be in a certain place is the sealing bit, we can use double-sided adhesive paper on the sandpaper paste in do not want to light the edge of the edge, so as to get an insurance does not hit should not be polished place.
6. Use the front and back pulling head and plane boots to save the plane, plane boot handle try to put flat not more than 25o, because the slope will hit a lot of rough lines in the mold.
7. If you do not use the front and back of the head with sandpaper boots to save the plane, manually also as far as possible to use the plane boots with adhesive double-sided adhesive sandpaper polishing, because this polishing molding will be relatively smooth, unevenness is greatly reduced.
8. If the mold plane is too small, do not use the front and back of the gun clamped oil stone into 30o or 45o hit, this will cause the plane uneven. Should be ground into a fine grain oil stone with bamboo or before and after the gun with a copper handle to press the oil stone light to remove the roughness of the sandpaper after polishing.
9. Use a copper or bamboo sheet to press the sandpaper to lighten the sandpaper and keep in mind that the sandpaper should not be larger than the area of the tool so that the place that should not be hit is hit by the extra sandpaper to the rounded mouth or become uneven status quo.
10. Use a fine or large flint boy when tightened in the sanding machine, use the flint king to hit to the same stamen or the shape you want, because the flint with the stamen to hit to the plane will be slightly smooth, stable. Use flint to hit the mold piece is suitable for roughing, because the flint boy processing will cause a lot of waves and unevenness.
11. With copper or bamboo sheet processing, the shape of the tool should be similar to the mold so as not to save the mold to deformation. For example, use flat bamboo sheet for flat surfaces and small or round bamboo sheet for small or round surfaces.
12. When lightening the plane to the side of the enterprise, sandpaper or oil stone should be played diagonally 15o to 30o lightening, so as to light with the large plane does not cause a deep pit in the side of the enterprise.
13. When rough polishing oil stone in 150 #, 180 #, 220 # and other oil stone should not be added to the fire water, except for polishing more than 320 #. Such as when the rough polishing oil stone in 150 #, 180 #, 220 # and other oil stone should not be added to the fire water, except for polishing 320 # or more. If you use the front and back to pull the head of the general sandpaper should not be added to the fire water polishing, manual use of copper or bamboo depending on the environment at the time.