January 12, 2021 in Uncategorized
The Process Itself. A conceptually different step to prevent pinching and allow forming of more complex parts applies appropriate lower internal pressure while the die is closing and higher pressure after the die is closed.
The steps and benefits of pressure-sequence hydroforming are displayed here.
Varying low pressure during die closing makes the fluid-filled tube act as a semi-solid and forms the part by supporting the tube wall on the inside while the cavity surface defines the outside. The tube wall is forced into the corners as the die closes, because the cavity is designed to be nearly the same periphery as the start tube. The tube wall, which is not stretched or thinned, fills the die cavity.
This compressive force, combined with low pressure, makes it easier for metal to overcome friction and move over the cavity surface without lubricants, making very Polyurethane injection grouting unnecessary.
When the die is closed, higher pressure is required to complete forming the tube walls. Holes then are pierced by punches mounted in the forming die. Lubricants are not applied, nor are they advantageous in PSH.
PSH hydroforming fluid provides limited rust prevention. The highest pressure used to finish forming the part can be whatever is required (for example, 172+ MPA, or 25,000 PSI).
The PSH method can apply high pressure when it is needed, such as in expansion without end feeding. However, it requires bigger and more expensive equipment and somewhat longer cycle times. All possible ways to create a part feature should be explored to find the most economical solution. High pressure should be used only when it is the best alternative and justifies the extra cost.
Normal high pressure for PSH is 34 to 69 MPA (5,000 to 10,000 PSI). Using high-strength material, thicker walls, and sharp (3T) corners has minimal impact on required pressure.
That forming the tube causes the material to yield by bending from the starting round to a finished shape of flat areas and forms sharper corners along its whole length. This nearly eliminates springback of the cross section and dimensionally stabilizes the whole part.
Part features. In this author’s opinion, the range of features in PSH is potentially even wider than for HPH. All of the available elongation for a particular material can be used to form the part rather than using a portion of it to avoid pinching. If a part can be bent, it can be pressure-sequence hydroformed.
Elongation needed for hydroforming is relatively low. In production, joint-free parts with bends up to 120 degrees and bend radii down to 1.5D can be formed, while other methods may require joining two or more parts. Fewer parts and joints tend to reduce cost, weight, and dimensional variability.
Additional operations, if any, are minimized, and the problems caused by making the cavity bigger than the start tube are avoided.
Local severe deformation can be built into a part to fit with another part, to avoid interfering with it, or to form a feature that causes a die lock condition. An actuator forms the feature when the die is closed.
Pressure sequencing is less demanding on material formability. It is designed to allow use of materials specified by the customer for best part function and economy, with no need to tailor the material properties to suit the process. This allows the use of mild steel, stainless, HSLA, and galvanized steel, high-strength lower-elongation material, and aluminum.
Yield strength increases 5 to 7 percent with PSH for mild steel, similar to that achieved by HPH. The whole cross section yields, bending to form the finished shape from the starting round.
N-value, a feature critical to HPH success, is of little concern with PSH, which in normal steel- or tube-making is not watched closely.
Die Considerations. PSH dies are finished to normal die standards. Some have run up to two million parts, with no die surface refurbishment or wear inserts needed.
Hole changes can be easier and less expensive than those for stampings. Hole punching capability is well-developed in the PSH system. Hole sizes in production range from 3.1 millimeter (0.122 inches) diameter to a 40- by 45- millimeter (1.575- by 1.772-inch) rectangular slot.
Holes punched in the fashion illustrated here are used for numerous applications, like self-tapping screws, clips, and pins.
At one company, more than 100 million holes currently are punched every year, with as many as 57 holes in one die. These numbers reflect customer need, not limitations. Holes are used for self-tapping screws, clips, pins, drainage, access, and other applications.
Lower internal pressures increase the hole count in the hydroforming die because punch cylinders can be smaller and the die strength needed to resist pressure lower.
Equipment. Factors such as corner sharpness, material strength, and thickness that increase HPH equipment size requirements make little difference for PSH. With the PSH process, forming the same part requires about 20 to 30 percent of the internal pressure and equipment needed for HPH. Large end-feed cylinders are not required except for expanded sections.
Section Expansion Before and During Hydroforming. Figure 8 shows 15 percent tube expansion without end feeding during normal pressure sequencing using less than 48 MPA (7,000 PSI). Expansion with end feed modifies the process pressure curve to minimize wall thinning with 55 MPA (8,000 PSI).
Mechanically expanding the round tube after bending and before hydroforming thins the wall (7 percent for 41 percent expansion) less than does hydroexpansion in the die (14 percent for 41 percent expansion), because friction aids end feeding in the first situation rather than resisting it, as in Injection Packers.
Cycle Time. Production cycle time for the engine cradle is less than 22 seconds, including handling and forming. The 35 percent lower cycle time allows 55 percent higher production capacity from one production line.
December 29, 2020 in Uncategorized
Many Homeowners with Poured-in-Place Concrete Foundations will find Cracks in their Basement Walls on Closer Inspection
Basement cracks develop by drying shrinkage, thermal movement, and other causes. If minor, they will cause no immediate problems. But over time, minor cracks often grow larger and cause major headaches, including reduced structural integrity or water leakage.
Homeowners with a leaky basement can have these cracks fixed permanently. Often without costly, disruptive excavation by using pressure injection with epoxy resin or water activated, hydro-active polyurethane foam repair materials.
We now offer Do It Yourself Basement Waterproof Resin Coating Products as Kits for leak repair and structural basement crack repair.
By sealing smaller cracks with a DIY Crack Repair Kit, the homeowner may save a significant amount of money. Even if a crack is not leaking yet, eventually water might find a way through it. We supply commercial grade epoxy resins and leak seal water activated polyurethane foams for all types of foundation crack and wall crack repairs.
Crack injection has been performed and improved on for several decades. In many cases, crack injection will fix the problem. The injection procedure will permit to fill the crack in full, from front to back, with epoxy resin or polyurethane grout. Injection has shown to be effective for filling cracks from 0.001 to over 2 inches wide. It can also be used to fill cracks in concrete floors and ceilings.
In most cases homeowners can have these cracks fixed permanently without costly, disruptive excavation—using pressure injection of epoxy resin or polyurethane water stop foam repair materials.
Many Concrete Block Walls Leak
You may find damp areas in your block wall or even active leakage from grout lines in your wall. Check the perimeter of your wall and the cold joints where the wall meets with the foundation or floor for leaks. Fresh concrete does not bond well to existing concrete – a cold joint is created. If not properly waterproofed, a cold joint will be a passageway for water migration.
In many cases homeowners can have these cold joints fixed permanently without costly, disruptive excavation—using basement waterproofing products such as pressure injection polyurethane water stop foam and leak-seal injection repair materials.
We offer Do It Yourself Kits for Basement Leak Repair
Polyurethane Waterproof Coating and epoxy injection are water stop, leak seal and structural repair systems used by thousands of applicators world wide. Basic product knowledge helps users and specifiers to reduce possible problems. The right injection technology should be identified before the project is started. This brief overview is designed as a basic guideline for your decision making.
Products have been developed for professional use and commercial applications. It is advised that product knowledge and product application knowledge is necessary for good success. It is our recommendation for homeowners to have basement repairs performed by a professional applicator.
We have received many testimonials over the years from savvy homeowners that have performed the repairs themselves after studying the product and procedure prior to application.
December 15, 2020 in Uncategorized
An Injection Packers is the connecting piece between your injection pump and the structural element for the injection of various sealing chemicals, including Epoxy resins (EP), Polyurethane (PU/PUR/SPUR), Polyurea, Acrylate Gel, Hydro Active Foam Grouts, Siloxane, Silification products, Micro emulsion, Slurries, Cement and injection mortar…
In the market, there are steel packers and aluminium packers but we decided to produce only plastic injection ports because they cover a large range of applications and can handle low and high pressures. Also, Plastic packers are inexpensive, set very quickly increasing productivity on the job site and are easily disposable after use (called « One day packer »). Last but not least, their lightweight enable you to save money on shipping.
Each mechanical injection packer has different characteristics
What are the different types of injection packers (kind of connection)?
To fasten your hose or gun on the injection packer, the top part could be:
Zerk fitting / With head / Nipple grease nipple / Moulded round head nipple
Button Head / Flat head
Pneumatic head / Air plug
The most popular connection is the Zerk type for the widepread availability of the injection equipment with 4 jaw couplers and its quick set up/disconnect.
The Button-top allows a more secure connection to the port, minimizing the leak issue and allowing the technician to be on the side during the injection in case of blow-out of the packer if they exit the drilled hole.
What diameter of packer should I use?
In most construction materials, the size of the drilled hole equals the outer diameter of the mechanical packer: use a 12mm drill bit for a 12mm packer. But if the construction material is brittle you may use a smaller drill bit.
Usually, a larger packer has a better grip and permits higher injection pressures but larger boreholes can damage the structure.
The choice of the inner diameter of the packer depends on the volume to be pumped and the thickness of the chemical resin injected.
Are there different lengths of injection port available?
Sizes of our injection ports vary from 15 mm to 80 mm.
In a few applications, such as the curtain injection, where the chemical injected inside a building should reach the other side of the structure, extension rods can be adapted at the bottom of the injection-packers. There rods can be cutted to the length of your need.
What is the purpose of a check-valve and its location inside the injection packer?
A few injection ports haven’t got any check-valve, for a free passage of slurry, cement or injection mortar. To prevent back-flow, a cap can be adapted to the packer’s top.
Most of our plastic injection packers have a 3mm metallic ball valve to prevent back splashes of chemical and force the injection material to remain and diffuse inside the structure.
This large inner passage is useful for the injection of thicker products.
When a 2-stage injection is needed in a structure with cavities, hollows and voids, a mix of two systems is possible:
– Cement injection through a Ø12mm injection-packer without valve to consolidate the structure
– Insertion of a Ø6.5mm injection-packer inside the Ø12mm one, to provide a non-return system and to inject your chemical resin under pressure.
In the Polyurethane injection grouting, the check-valve is situated on the top part because, after the injection, the packer is pushed inside the bore hole and remain in the structure hided with a suitable sealant.
December 8, 2020 in Uncategorized
anaging an analytical instrumentation operation is no small feat. Whether you design, construct, operate, or maintain a High Pressure Grease Fitting‘s sampling system, receiving consistent, reliable results can be a struggle for even the most seasoned engineers and technicians. Issues with your sampling system can spell major problems for your plant such as: resource downtime, operational inactivity or unexpected maintenance costs.
Luckily, there are several areas your team can regularly monitor to improve system efficiency. Learn how to diagnose and eliminate issues associated with your sampling system with these ten tips.
1. Check for simple system errors.
You can improve the reliability of your analyzers by auditing and eliminating simple mistakes from your sampling system installations, such as reversed check valves blocking your sample flow or a fast loop flowing backwards. Luckily, these instances are easy to find and remedy.
2. Reduce gas volume upstream.
High-pressure gas can ruin a well-designed sampling system by causing condensation in the lines and excessive time delay due to gas compressibility. Furthermore, high-pressure gas can present itself as a safety concern due to rapid decompression in the event of a component failure. It’s best to reduce the pressure of a gas as soon as possible and to minimize the sampling system volume on the upstream side of a regulator.
3. Keep pressure on liquid samples.
Liquid samples behave just the opposite of gas samples. Letting the pressure drop may release a dissolved gas, thus causing the liquid to bubble or foam. It’s best to keep the pressure of a liquid sample as high as possible.
4. Pay attention to system surfaces.
When fluid touches a surface, several molecules are left behind. Loss of molecules due to adsorption can spoil your sample. Pick the proper materials for filter elements, regulator diaphragms, tube walls, or gas cylinders. Also, be sure to consider the ambient environment. For instance, 316SS tubing can be damaged by the chlorine in seawater while polymer tubing can become brittle after UV exposure.
5. Use compatible elastomer seals.
Materials that are mismatched to your sample fluid may cause failures like sample leakage or even a blockage within the sampling device. Be sure to use compatible elastomer seals to ensure to an accurate sample analysis.
6. Avoid sampling from stagnant lines.
For a representative sample, make sure you’re sampling from an active and flowing process line. Remember that the timeliness of your sample is also dependent on the time it takes the sample to flow from the process to the extraction point. The location of the sample point can be a critical aspect of a successful sampling system.
7. Look for dead legs in your sample transport line.
A common problem for technicians and engineers alike is “dead legs,” or an unpurged volume. This issue allows molecules to be held up from earlier samples to diffuse into your current sample, causing a slow analyzer response and the continuous contamination of your system.
8. Keep vaporizers cooler.
A hot vaporizer body could boil the incoming sample, causing it to fractionate. Make sure you understand the temperature requirements of the chemicals in your system and appropriate equipment settings to prevent errors.
9. Maintain sample flow.
Success in Surface Packerss’ sampling is largely a matter of ensuring the sample fluid remains at the right flow, pressure and temperature to bring the fluid into an appropriate condition for analysis. Controlling those three conditions might be enough to eliminate many of the problems plaguing process analyzers around the world. Generally, a faster flow is recommended to ensure good sample mixing, cleaner sample lines, and quicker response time.
10. Identify the causes of time delay.
If your measurements do not appear to be tracking with your process, you may have time delay in your system. Other symptoms of time delay include blurred or muted responses, laboratory disagreement, and poor performance of a control scheme.
November 24, 2020 in Uncategorized
Water jet cutting is a process by which materials are cut with a water jet under High Pressure Grease Fitting. For very hard materials, an abrasive (abrasive material) is added to the water jet to increase the cutting power. Almost any material can be cut with water jet cutting machines.
The combination of an accurate water jet cutter with smart software from our water jet cutter ensures higher cutting quality. This cutting head is available for 2D, 2.5D or 3D cutting.
What are the differences between these three ways of water jet cutting? You can best explain this by looking at the cutting result.
2D cutting is simply the cutting of contours from a material. With 2D cutting, the cutting head from which the water jet comes does not change in position with respect to the material to be cut. The cutting head always remains perpendicular to the cutting bed. With Resato machines, the cutting bed is horizontal and the cutting head is vertical. The 2D cutting head therefore moves forward, backward or sideways and always remains at the same distance from the object to be cut.
The 2.5 D cutting head is designed to cut sloping parts from material. The cutting bed remains horizontal, but the cutting head can tilt up to 55 ° in all directions. This makes it possible to cut sloping sides.
This is used, among other things, when preparing weld seams, so-called V seams, such as, for example, in counter tops that must be glued together. Or in the case of design issues.
Here too, the cutting bed remains horizontal, but the cutting head can also tilt up or down by 55 °. The cutting head thus follows the shape of the cutting material. It is therefore possible, for example, to cut bulges. 3D water jet cutting is a fairly young technique and is currently being used very successfully in finishing castings to cut away Surface Packers. But there are many more applications.