Summary
Toolcraft, a leader in precision manufacturing solutions, designed and manufactured a Brass Die scraper for an esteemed industrial manufacturer. This essential component is engineered to enhance efficiency in their manufacturing processes by effectively removing excess material from dies, ensuring optimal product quality and consistency. This case study details the specifications, applications, manufacturing process, and quality control measures undertaken to deliver this critical component.
Project Overview
Product: Brass Die scraper
Industry: Industrial Manufacturing
Overall Specifications
- Material: 360 Series Brass
- Stock Dimensions: 3/16″ x 3/8″ x 8-1/2″
- Quantity: 12 pieces
- Tolerance: Maintained within +/- .015″
Uses and Applications
The Brass Die scraper is designed for various industrial manufacturing applications, including:
- Material Removal: Efficiently removes excess material from dies in the production of rubber products.
- Precision Operations: Ensures high-quality and consistent product output by maintaining die cleanliness.
- High-Volume Manufacturing: Suitable for extensive use in demanding industrial environments.
Capacity
The Brass Die scraper is capable of handling extensive production demands, enhancing operational efficiency and productivity. Its robust design ensures prolonged use under high-stress conditions, making it ideal for continuous industrial operations.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Utilization of certified gage blocks & gage pins, a digital height gage and other inspection equipment to check the first article part.
- In-Process Gaging: Parts were periodically checked by the machinist during production before heading to final inspection.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Design & Engineering
Toolcraft’s engineering team collaborated with the client to understand specific requirements. Advanced CAD software was used to design the Brass Die scraper, ensuring compatibility with industrial applications and optimization for performance.
Material Selection & Procurement
High-quality brass was chosen for its superior properties and suitability for the application. Materials were sourced from certified suppliers to ensure quality and consistency.
Precision Machining
Utilizing Toolcraft’s state-of-the-art CNC machining capabilities, the Brass Die scraper was manufactured with tight tolerances to ensure precise fit and function. Multi-axis machining centers were employed to achieve complex geometries and features.
Polishing & Finishing
The scraper underwent a meticulous polishing process to ensure a smooth and effective tool, enhancing its operational efficiency.
Assembly & Testing
The machined components were meticulously assembled in Toolcraft’s controlled environment. Each step was monitored to ensure alignment and proper fit.
Conclusion
Toolcraft’s expertise in precision manufacturing and commitment to quality enabled the successful development of the Brass Die Scraper. This critical component enhances the capabilities of the client’s manufacturing operations, providing reliable and efficient solutions for a wide range of applications. Through meticulous design, manufacturing, and quality control processes, Toolcraft ensured the delivery of a robust and versatile component tailored to meet the specific needs of their client.