Lifting Magnets: Are They Worth It?

There are three ways to increase your profits. You can increase your rates. You can work on increasing the number of customers. Or you can try keeping operating costs down. Keeping operating costs down is the easiest. Increasing your rates can drive away customers. Increasing the number of customers is largely dependent on market demands. Keeping the operating costs down is entirely within your control.

Part of operating costs is the procurement of shop equipment.  Being smart and not buying something that is not needed or does not provide any benefits to your operation is a good way to keep the operating costs down. When thinking of purchasing an equipment, it is always important to ask, "Is it worth it?" Let us look at lifting magnets.

Lifting magnets are just one of the many magnet tools used in shops everywhere. As the name suggests, lifting magnet is a magnet tool used for lifting and moving materials around the shop, from the floor to the table or from one table to another. Lifting magnets have a wide range of lifting capacity. The more powerful lifting magnets can carry up to 3000kg.

Lifting magnets make moving heavy stuff faster and safer. It improves productivity and quality of work by allowing the worker to focus his effort on technical work instead of manual labor. It also prevents injuries caused by constantly lifting and carrying heavy materials.

Lifting magnets, especially the permanent ones, are a one-time expense. They don't require electricity to work and require minimal maintenance. As far as equipment goes, the lifting magnets are definitely worth the buy for shops that deal with heavy workpieces.

Ergoboll

Magnetic boards or tables are standard tools in most shops. The tables anchor metal workpieces to prevent unwanted movement during machining processes without needing the use of clamps. This magnetic tool makes it easier and faster to set up the position of the workpiece. This way, machine operators can proceed with the machining process instead of spending so much time perfecting the setup.

The ergoboll is a type of magnetic board mounted to a ball. It has the same functions as conventional magnetic boards, which is to secure workpieces in place. However, the big difference is that the ball can be rotated freely to provide the best ergonomics and leverages when working. This increases precision and productivity, as well as protect the wellbeing of workers.

Instead of moving around the and contorting into uncomfortable positions, a worker can adjust the angle and orientation of the workpiece for ideal working leverages and comfort while staying in place. This magnet tool helps relieve the shoulder and neck and prevent injuries.

The advantages of an ergoboll can be felt in precision and time-intensive processes. The ergoboll comes in different sizes to suit the type of application and availability of space inside the shop. It comes as a permanent or electromagnet. It is an excellent alternative to large tilting magnetic tables.

EDM, Graphite Electrodes, and Quality of Finish

Many expected the use of EDM or electrical discharge machining to dwindle at the turn of the century due to the development of new machining technology. More than a decade has passed since the prediction but EDM remains in use and preferred by many workshops. The reason for this staying power is the lower cost of operation, reliability of EDM machines that allowed them to stay in very good condition, and quality based on the experience of the operator. A newer technology might offer far better potential in terms of quality but until an operator is able to master its operation, that potential will remain as is.

Graphite electrodes have also made EDM machines for applications that are more than just rough cutting. The graphite used for electrodes in sinker EDM have varying grades. The type of grade determines the quality of finish.

Fine grade graphite electrodes are made of particles with sizes between 11 to 20 microns. These electrodes are primarily used for roughing in large cavities in work pieces. The finish is very crude and will require further polishing down the line. Polishing equipment like diamond tools can be used for improving the quality of the work piece right after the EDM process.

The superfine grade graphite electrodes feature particle sizes between 6 to 10 microns. These electrodes are used for creating cavities that larger details. The quality of finish is still very crude will require polishing.

The ultrafine and angstrofine grade graphite electrodes are the ones used for finishing applications. Ultrafine grade features particle sizes of less than 5 microns while angstrofine have submicron particles. These are used for creating intricate details with very high quality finish.

How To Properly Store Magnet Tools

A workshop relies on a multitude of tools to complete projects. Every piece of equipment is an essential investment that should be protected. The magnet tools are important in completing a plethora of tasks. There are lots of types of magnet tools utilized in shops. There is a magnet tool for picking up and transferring heavy items and there is a magnet tool for locking in work pieces. It might not be as costly as the diamond tools, but the magnet tools are equally as useful to any type of workshop when it comes to getting a job done.

A magnet tool requires proper storage to optimize its serviceable life and to stop problems that could negatively affect its performance. All magnet tools need to be stored at room temperature. Exposure to extreme heat can cause a magnet to lose its magnetism. With this in mind, the storage space for the magnet tools needs to be away from equipments that produce heat.

Lots of magnetic materials are susceptible to corrosion. The moisture inside the storage space needs to be controlled to stop damages brought on by corrosion.

Magnets are fairly heavy. Accidental impact between magnets or between the magnet and other hard objects can lead to damage. A formed foam or plastic can keep the magnet tools safe from impacts and minimize movement that helps prevent damages in case the storage box is dropped.

These are just a few of the fundamentals of the correct means to store a magnet tool. There are several more guides on proper storage that are specific to the kind of magnet tool.

How Graphite is Made

Graphite is the most preferred electrode material for sinker EDM applications. It has been over half a century since graphite was introduced to the EDM industry. But even with the modern advancements in machining technology, graphite electrodes remain an integral part of the industry. It is cost-effective and provides excellent results. It is similar to diamond tools that have also withstand the test of time and the arrival of new technology by being easy, affordable to use and providing the needed results.

Graphite is made using carbon powder which is derived from petroleum. The carbon powder is mixed with a petroleum-based binder. The mixture is then compacted to create a block. The way the graphite is compacted greatly influences its properties. In the early days, graphite was made by compressing the mixture in only one direction. This resulted to the formation of grains. These grains affected the structural strength of the formed graphite and other properties like resistance to wear and machinability.

The needs of the aerospace industry resulted  a newer method of compacting the carbon-binder mixture. The isostatic pressing of the mixture created blocks with uniform properties all throughout.  This compacting process is used to produce the modern high-quality graphite which is used for sinker EDM electrodes. The block then undergoes several heat treatments that converts carbon to graphite. The fineness of the carbon powder determines that finishing quality of the EDM.

Laser for Microdrilling

Laser is one of the most accurate methods for cutting materials. Its ability to cut all sorts of material makes it a valuable equipment in machine shops all over the world. Flat laser cutting, for example, is used for fast and easy cutting of sheet materials such as metal, plastic and wood. 

The lack of debris makes it all the more important in operations wherein the risk of contamination is a serious issue. Aside from cutting, an application wherein the use of laser tops all other methods is for microdrilling.

Not very long ago, the smallest hole that could be made using the conventional method was the size of a human hair. Advancements in the realm of medical, computer and electronic technology require the drilling of even smaller holes. 

These holes have to be accurate, straight and have the necessary geometric details.

Non-conventional drilling technique was needed which necessitated the development of new machining tools. The ultraviolet light lasers is one of the best tools for microdrilling and other micro machining applications. 

It had high peak power and repetition rates which makes quick work of machining tasks. The quality of the beam produced allowed the drilling of holes with diameters as small as 10 micrometers.

The use of laser for microdrilling has been around for quite a bit of time. The aerospace industry used this method in the production of components of the aircraft turbines. This technique, however, did not catch on quickly for other machining operations. 

This is due to the fact that these types of laser systems used to require a great amount of maintenance. Plenty of replacements such as those of optics and flash lamps have to be done in order to keep the system running.

Graphitization of Diamond Tools

The diamond is the hardest material in the world. It also has a very high temperature tolerance. This makes it one of the most effective components in cutting tools.

Diamond tools are most widely used in superfinishing, otherwise known as microfinishing. This is a metal working process that improves the surface finish of the work piece. This is done by removing the amorphous layer that is left from previous abrasive processes. Superfinishing  creates a cross-hatch pattern on the workpiece. If performed at high and fine speeds, this can create a mirror-like finish.

Diamond tools, however, are not suitable for cutting steel as this can result to severe wear on the tool. This makes it inefficient and unprofitable .

The severe wear occurs due to graphitization, a process that turns the crystal structure of a diamond into a graphite crystal structure. Carbon steel and alloys with cobalt, nickel and titanium can cause graphitization.

Plenty of efforts have been made in an attempt to make diamond tools viable for cutting steels. One method is to perform the cutting process in specially designed chambers that prevent graphitization.

Since graphitization only happens at temperatures above 200 degrees Celsius. In a cryogenic chamber, a diamond tool can be used for cutting steel without the problem caused by graphitization. The problem with this and other similar methods is that the equipment needed for the setup is quite expensive which is not ideal for many who are running a smaller operations.