Take the fabric stretching function as an example:
1. Operation adjustment
(1) Clamping distance adjustment
Before the instrument tensile test, the clamping distance between the upper and lower clamps must be adjusted to be consistent with the set value. The specific adjustment method is:
①. Press the up button on the control panel to make the crane rise. After rising a certain distance, press the stop button to stop the crane.
②. According to the required length of the sample, move the lower limit block to the position of the corresponding hole (or indicator arrow) on the limit rod and tighten it. The limit rod is drilled with a lower limit positioning stop hole for positioning the lower limit collision block. Each hole indicates the clamping distance of the clamp to be tested.
③. Press the down button to make the crane descend to the lower limit position and stop automatically. Use a steel ruler to measure the distance between the upper and lower clamps. If there is a slight difference with the clamping distance requirement, the height of the upper limit collision nut can be adjusted (thread adjustment) to finally make the distance between the upper and lower clamps consistent with the clamping distance requirement.
④. According to the adjusted distance between the upper and lower clamps, check whether it is consistent with the set clamping distance. If not, repeat the above steps until it meets the requirements.
(2) Selection of pre-tension clamps
According to the specifications of the specimen, calculate the pre-tension value required for clamping the specimen according to the test standard, and then select the corresponding pre-tension clamp. (3) Test parameter setting According to the standard requirements, enter the value as prompted by the LCD screen. (4) Adjustment of stretching speed When testing a specimen, prepare a number of additional specimens more than the specified number of test strips for preliminary testing to determine the stretching speed.
(3) Test parameter setting
According to the standard requirements, enter the value as prompted by the LCD screen.
(4) Adjustment of stretching speed
When testing a specimen, prepare a number of additional specimens more than the specified number of test strips for preliminary testing to determine the stretching speed.
2. Clamping the specimen specimen clamp
According to the customized function configuration, take the corrugated clamp for fabric stretching function as an example:
a. Rotate the clamp handle to loosen the corrugated clamp;
b. Insert one end of the test strip from the bottom of the upper clamp into the opened upper clamp clamping mouth, and keep the specimen and the jaws straight:
c. Rotate the handle to clamp it;
d. Loosen the lower clamp handle to open the lower clamp jaws;
e. Pass the other end of the test strip clamped in the upper clamp through the lower clamp jaws, and clamp the strip through the jaws with the selected pre-tension clamp so that the specimen is straightened under the action of the pre-tension clamp;
f. Rotate the lower clamp handle to clamp the lower end of the specimen, and then remove the pre-tension clamp, and the specimen clamping is completed.
3. Tensile test
Press the start button on the base, the crane rises, and stretches the sample clamped between the upper and lower clamps. After breaking, the crane automatically returns to its original position, and the instrument automatically records and displays the maximum strength value (peak strength value), tensile length, elongation, breaking time and test number at the time of breaking.
4. Check and process the test results
①. Check the fracture position of the sample. If the distance between the fracture and the upper and lower clamp jaws is s5mm, cancel the test value and re-test. Press the delete key, and the instrument will process the test value accordingly (minus one, the test is invalid).
②. If the fracture position of the sample is normal; the test is valid, the strength and elongation curve of the test can be printed at this time, and then check the test number value. If the sample display value (the number of tests for this type of sample) is consistent with the set value, it indicates that the test of this type of sample is completed. Replace the new sample and continue the test; if the display value is less than the set sample value, repeat the previous action and continue the test on the strip sample of this type of sample.
5. Printing test report
After the sample has been tested for the required number of times, that is, when the sample display value is consistent with the set sample value, it means that the test of this sample has been completed and it can be printed at this time. When printing, press the print key, select the print format, and then print the test report after confirmation. Before printing, ensure that printing paper should be added to the printer; in addition, the printer's online indicator (ONLINE) must be on. After printing, you can continue to test, and press the print key later to print. If you need to perform a new test after printing, you need to press the reset key and then test again. If you need to print repeatedly, press the print key again after printing.
6. Display the test results directly through the LCD screen on the display panel.
7. After one set of samples is tested, press the reset button to restart the instrument and clear the existing stored data in the computer so that it can start working again.
1. Each time you turn on the instrument and start a new set of tests, you must press the reset button to restart the instrument, otherwise the data processing will be incorrect.
2. When the instrument is reset and the zero key is pressed, it contains the function of automatically clearing (peeling) the force sensor. Please note that when starting the instrument, the upper clamp should not be subjected to any additional force except its own weight, otherwise, inaccurate peeling will lead to inaccurate testing.
3. The instrument input setting parameters should be performed before a set of tests begins, otherwise, data processing errors will occur.
4. The instrument has been calibrated for the strong force indication before leaving the factory. Non-professional calibration and maintenance personnel are not allowed to calibrate it arbitrarily, otherwise the instrument will cause inaccurate force measurement.
5. The force sensor can be cleared while waiting for the test and calibrating the display status. After pressing the zero key, wait 2 seconds before starting the test.
6. In the instrument automatic control program, there is a test value judgment program, which will automatically delete the obviously wrong test data (including the measured value after the sensor zero point drifts seriously and the impact strength value); please note that if the instrument automatically deletes the current test value for many times in a row, it is generally because the reset value has been offset. You should press the reset key to reset it again before continuing the test.
7. The maximum allowable setting of the sample value and the number of sample varieties of this machine are limited to 255 times. At the same time, the number of samples × the number of samples <500, the computer automatically determines whether it is a memory overflow and prompts with text on the LCD screen.
8. If you want to print the test curve, you should print it after the current test is completed, that is, only print the current test curve. If this test is the last test of this group, print the curve first and then print the report.
9. Note that the force on the upper clamp should be less than the full scale value of the instrument. Avoid the impact of the upper clamp, otherwise it is easy to damage the force sensor.
10. Clean and maintain the instrument well, and lubricate the screw and guide rod in time.
11. Regularly calibrate the instrument to ensure the accuracy of the instrument's measurement value.
12. Non-professional maintenance and calibration personnel are not allowed to dismantle the instrument. The measurement performance must be calibrated after each dismantling to avoid instrument inaccuracy.
13. If there is a sudden failure during operation, emergency stop must be performed and restart must be performed.
There are many types of shoe material testing equipment, which are used to test various properties of shoe materials. The following are some common shoe material testing equipment:
Toe bending test machine: used to test the bending resistance of finished shoes and evaluate the bending resistance of shoe materials.
Upper leather stretch test machine: simulates the compression, stretching and bending of the upper during walking after wearing shoes.
Leather wear test machine: suitable for the wear resistance test of wear-resistant materials used on the heels of leather shoes.
Bending test machine: used to connect and bend test pieces of a certain size, and observe the degree of cracking and damage of the test pieces after a certain number of bends.
Leather shoe shank stiffness tester: suitable for the determination of the longitudinal bending stiffness of the leather shoe shank.
Safety shoe compression tester: suitable for steel toe compression and steel mid-plate puncture resistance test of all types of safety shoes.
Anti-puncture bending test machine: test the bending resistance of safety insoles.
Leather Flex Tester: Determines the material's resistance to cracking or flexing at a bend crease.
Rubber resilience impact tester: measures the impact resistance of elastic materials and soft porous materials.
Sole static anti-slip tester: tests the static anti-slip properties of outsoles, high-heeled shoe heels and related outsole materials.
Testing machine double-arm tensile machine: used for various materials for tensile, compression, bending, shearing, bonding strength, peeling, tearing and other tests, suitable for a variety of materials.
Low-temperature sole bending tester: examines the bending resistance of the sole under low temperature environment.
Whole shoe wear tester: suitable for testing the wear resistance of finished shoe soles and molded soles (sheets).
Heel impact tester: simulates the ability of women's high-heeled shoes to resist sudden impact when wearing and walking.
Safety shoe withstand voltage tester: tests the voltage value that the sole or insulating shoe material can withstand.
Water vapor permeability tester: measures the water vapor permeability of leather or synthetic materials used for shoes or personal protective equipment.
Anti-yellowing chamber detector: simulates sunlight to measure anti-yellowing performance.
Rubber soles and shoes ozone aging tester: Evaluate the weather resistance of rubber soles and shoes in ozone environment.
These equipments cover a variety of performance tests such as bending resistance, wear resistance, impact resistance, puncture resistance, voltage resistance, water vapor permeability, etc. of shoes, and are indispensable tools in shoe production and quality control.
Measuring shrinkage is one of the common testing methods for textile testing, but practice has proven that the shrinkage of textiles is affected by many factors. Therefore, understanding the factors that affect textile shrinkage has positive significance for the scientificity and accuracy of measuring shrinkage.
Common factors that affect textile shrinkage include:
1.Fiber composition: Compared with synthetic fibers (such as polyester, acrylic), natural plant fibers (such as cotton, linen) and plant regenerated fibers (such as viscose) are prone to moisture absorption and expansion, so the shrinkage rate is larger, while wool is due to the scale structure on the fiber surface. It is easy to felt, which affects its dimensional stability.
2.Production and processing process: Since the fabric will inevitably be stretched by the machine during the dyeing, printing, and finishing processes, tension exists on the fabric. However, the fabric can easily release the tension when exposed to water, so we will Noticed fabric shrinkage after washing. In actual processes, we generally use pre-shrinking to solve this problem.
3.Fabric structure: Generally speaking, the dimensional stability of woven fabrics is better than that of knitted fabrics; the dimensional stability of high-density fabrics is better than that of low-density fabrics. Among woven fabrics, the shrinkage rate of plain weave fabrics is generally smaller than that of flannel fabrics; while among knitted fabrics, the shrinkage rate of plain knitted fabrics is smaller than that of ribbed fabrics.
4. Washing and care process: Laundry care includes washing, drying, and ironing. Each of these three steps will affect the shrinkage of the fabric. For example, the dimensional stability of hand-washed samples is better than that of machine-washed samples, and the washing temperature will also affect its dimensional stability. Generally speaking, the higher the drying oven temperature, the worse the stability. The drying method of the sample also has a relatively large impact on the shrinkage of the fabric.
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In the wire and cable industry, accurate and reliable quality testing is an important link to ensure product performance and safety. Tophung is an enterprise specializing in the production of wire and cable testing equipment, and has long served many cable companies at home and abroad to explore the quality testing solutions of cable products in an all-round way. In the wire and cable industry, our main products are: TH-5806 Cable Bending testing machine, TH-5807 Cable 2D torsion testing machine, TH-5812 Cable vertical torsion testing machine, TH-5813 Cable drag chain bending testing machine, TH-5814 Cable 3D torsion testing machine, etc., these machines can be obtained from different repeated experiments. Detects the cable's performance of plastic deformation and displays its own defects.
Our company offers wire and cable bending testing equipment with a variety of flexible functions and technologies, enabling manufacturers to achieve comprehensive quality control and product improvement. Here are a few highlights of our diverse testing:
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ASTM (American Society for Testing and Materials) machines are specialized testing instruments designed to evaluate the mechanical and physical properties of materials according to ASTM standards. These machines play a crucial role in ensuring the quality, safety, and performance of materials used in various industries, including metal manufacturing, new composite materials, solar photovoltaic energy, wire and cable, automotive, and plastics.
At Suzhou TOPHUNG Machine Equipment Co., Ltd., we specialize in the research, development, production, sales, and service of high-quality ASTM testing machines. Our advanced testing equipment ensures that materials meet the rigorous requirements set by ASTM, enabling manufacturers to maintain consistency, reliability, and compliance with international quality standards.
Types of ASTM Testing Machines
ASTM testing machines come in various types, depending on the specific property being tested. Some common categories include:
Dynamic Fatigue Testing Machines – Simulate long-term stress conditions on materials and products.
Why Choose TOPHUNG for ASTM Testing Machines?
High Precision & Reliability – Our machines are built with advanced technology to provide accurate and repeatable test results.
Comprehensive Solutions – We offer a wide range of testing equipment, covering various ASTM standards for different industries.
Customization & OEM Services – We provide tailored solutions to meet specific customer needs, ensuring maximum efficiency and compliance.
Strict Quality Control – Each machine undergoes rigorous quality checks before delivery, ensuring long-term performance and stability.
Global Export Expertise – With years of experience in international trade, we supply ASTM testing machines to customers worldwide, offering professional after-sales support.
ASTM machines are essential for material quality assessment and compliance with international standards. At Suzhou TOPHUNG, we are committed to providing cutting-edge testing solutions that help businesses enhance product quality, reduce risks, and improve competitiveness in global markets. Whether you need material mechanics testing, photovoltaic testing, or cable testing machines, our team is ready to support you with top-notch equipment and technical expertise.
Universal testing machines (utm) play a vital role in various industries by examining the mechanical properties and properties of materials, components and finished products. These versatile machines can perform a wide range of tests, including tensile strength, compression, bending, shearing and more.
From automobiles to industrial machinery, gears are crucial components in a myriad of mechanical systems. They serve the purpose of power transfer. Their manufacturing demands high precision and often presents challenges. That’s where CNC machine gear cutting comes into play.
CNC machines use programmed instructions to cut gears and help achieve extreme accuracy. These eliminate manual intervention and error and ensure the required specifications. Custom designs and large-scale production can both benefit from CNC machining.
There are different tools and techniques typically employed for gear machining. Some focus on rough shaping, while others concentrate on smoothing. Knowing these techniques assists you in picking the most suitable process to fulfill your requirements.
What Is CNC Machine Gear Cutting?
CNC machine gear cutting is a subtractive process. Usually, it begins with a solid metal workpiece, from which bits of materials are removed using specialised cutting tools. The end goal is to produce gears with specific tooth profiles and dimensions.
The primary difference between manual machining and semi-automatic machining is that the latter is programmed ahead of time. It guarantees consistency, even in cases of complex gear designs, due to the automation of the system. The software is responsible for determining tool positioning, cutting speed, and depth, all for maximum accuracy.
Polar Coordinate Interpolation is useful for certain cutting techniques. Spur, helical, bevel, and worm gears have different cutting requirements due to their distinct shapes. CNC machines are capable of producing gears that work well with the entire mechanical system.
Design engineers construct the gears, and the CAD software designs interfaces as the software builds conditions for digitized blueprints on the machines. The automated system speeds up production. Beyond that, it reduces the likelihood of mistakes.
Importance of CNC Machine Gear Manufacturing
Before automation, the process of cutting gears was labour intensive. Moreover, each gear was produced slightly differently, leading to inconsistencies in performance.
CNC machines ensure all gears are produced reliably and are crucial for precision in gear manufacturing. Performance-critical tasks like maximized noise, vibration, and complete machinery failure can happen with insufficient and poorly-cut gears.
Virtually hundreds of gears can be manufactured with one setup and performed under minimal supervision. This efficiency lowers costs while adhering to factory quality standards.
Not limited here, CNC machine gear cutting leads to a minimized amount of material waste. The software calculates the most efficient route that can be taken to cut, making sure raw materials are used effectively. Besides, it makes CNC machining practices environmentally friendly. Because the costs are cut and sustainable practices are boosted.
Types of CNC Machines Used for Gear Cutting
The modern manufacturing industry utilizes various CNC machines for gears manufacturing.
CNC Milling Machines
CNC milling machines operate by utilizing fast rotary cutting tools. These eliminate material from original/raw metal blocks. The gear profiling outcomes are in exact dimensional shapes that maintain strict specifications.
The milling process easily allows manufacturers to create unique gears. The cutting parameters are adjusted. For example, with precise control over spindles, feed rate, and depth of cut, engineers can produce standard quality gears. CNC milling provides exceptional flexibility, which makes it optimal for creating prototypes as well as manufacturing gear products at low-to-medium production volumes.
Advanced models feature multi-axis control. Gear geometries that require intricate complexity become possible through machines with 5-axis operations. The machines can reduce production time and maximize accuracy through their ability to reduce object movement requirements.
Secondary finishing tasks are achievable through CNC milling machine operations. Following the first shaping operation, a secondary milling pass produces smooth gear teeth. It results in reducing both friction and wear.
CNC Lathes
Cylindrical gear components require CNC lathes as essential equipment. A lathes operates differently from other machines. Since it spins the gear blank while a tool removes material from its surface.
Lathes function best in the production of shafts together with pulleys and worm gears. By continuously rotating, its cutting tools perform uniform operations, which allows it to curate high surface quality and correct dimensions.
Modern lathes use live tooling systems to combine CNC turning and milling operations during one production run. The combined operation removes the requirement for independent processing technologies and speeds up production while increasing operational performance.
The aerospace sector, along with the automotive industry, heavily relies on CNC lathes for their high-performance operations. Modern machines can deliver precise and predictable results that are crucial for making critical gear components.
CNC Gear Hobbing Machines
Gear hobbing stands as the most effective approach to manufacturing gears. The hob tool rotates as it cuts gear teeth by continuous contact with the workpiece during the shaping process.
The machine system can produce all types of gear shapes, such as spur, helical, and worm gears types. The method generates a uniform tooth distribution and guarantees successful gear meshing operations.
Mass production becomes achievable through hobbing because it enables the simultaneous cutting of multiple gears. The continuous contact between hobbing tools and the workpiece during machining reduces tool wear and produces higher manufacturing efficiency than shaping does by its intermittent cutting method.
Current hobbing machines include robotic loading systems as part of their automated features. High-volume manufacturing becomes possible. Besides, it required limited operator interaction to maintain consistent quality across large production volumes.
CNC Grinding Machines for Gears
Gear manufacturing requires grinding as its final operational stage to achieve accurate tooth profiles and excellent finish quality. CNC grinding machines use abrasive wheels for the removal of tiny defects on gear surfaces.
The machines deliver outstanding precision, even up to micrometer levels. The automation and aerospace sector heavily relies on CNC grinding to produce their exacting gear component requirements.
In addition, grinding extends the service life of gears through its ability to decrease friction. As a result, it usually produces less material wear over time. The manufacturing process leads to better reduction, which becomes essential for high-speed gear operation.
Modern grinding machines utilize self-operating measurement capabilities. Real-time gear dimension verification allows machines to change parameters during operation. Therefore, design manufacturers can achieve perfect accuracy and production consistency.
CNC Machine Gear Cutting Techniques for Precision Manufacturing
CNC gear-cutting techniques cover several approaches to shape different types of gears. The contemporary CNC machining sector depends on various standard manufacturing. Let’s examine some of the common options.
Hobbing Process
Mass production of external gears becomes highly efficient through the Hobbing Process. Manufacturing gear teeth depends on a hob, which synchronizes rotation with the workpiece to achieve exact cuts.
It is used for making spur, helical, and worm gears. Hobbing machines with CNC control enable the optimization of tool rotation speed together with feed rate and cutting depth, which produces exact gears profiles.
The CNC hobbing machines automatically change gear profiles because they optimize their cutting processes based on material types and hardness specifications.
Shaping Process
The gear-shaping operation can precisely manufacture both external and internal gear components. The gear teeth creation takes place through the gradual movement of a reciprocating cutting tool.
Shaping can produce internal gears and complex gear contours. These types cannot develop effectively through hobbing. Manufacturers widely use shaping in planetary gear systems and compact mechanical assemblies.
The adaptability function stands as one of the crucial advantages of shaping procedures. The CNC shaper provides flexibility to handle diverse gear measurements combined with multiple tooth designs that allow processing complex gear layouts. The process of shaping requires more time than hobbing. Therefore, it is notable for making gears at lower production scales for specialized purposes.
Broaching
Broaching gives accurate and fast operations to produce keyways along with splines and special gear features. The process uses a toothed tool that travels straight along the workpiece while it builds up the target profile features.
Usually, it succeeds best at manufacturing strong gears destined for the aerospace and automotive industries. CNC broaching machines deliver precise results and dependable operations that allow them to manufacture critical engine and transmission components.
The final use product is accomplished through the grinding process. The process removes small surface defects, which leads to better gear efficiency and lower operational noise.
CNC Gear Cutting Applications in Various Industries
Here are common industries that use gears for multiple components.
Automotive Industry
The production of automobiles heavily depends on CNC gear cutting operations. The precision of the gear produces smooth transmission performance, which increases both friction and wear levels. High-quality gears do not merely increase fuel economy but also the operational longevity of vehicles. The machine tools from CNC technology produce differential gears, transmission gears, and camshaft gears while maintaining precise dimensions.
Aerospace Industry
The aerospace industry requires strong lightweight gear components for its operations. CNC machining leads to parts that achieve exact dimensional requirements important to flight safety. Gears used in aerospace technology must shoot with the ability to stand up against high stresses coupled with stable temperatures. CNC gear grinding and hobbing operations produce perfect results for aircraft engines and navigation systems.
Heavy Machinery and Industrial Equipment
Machine centers enable the production of industrial machinery gears that require heavy-duty capacity. The gears used in construction, mining, and agricultural equipment need to be strong and generate high torque. CNC machining creates gears resistant to heavy loads when operating under adverse environmental conditions.
How To Select an Appropriate CNC Gear-Cutting Machine?
Picking the perfect gear-cutting cutting machine involves more than simply acquiring a spindle with high rotational speed. The selection of machines revolves around three main elements. These are precision, durability, and operational efficiency. Here are the aspects to consider before making a choice.
Material Compatibility: Choose The Right Machine for the Right Job
All CNC machines show different responses when processing materials. A machine that works with hardened steel requires both high-torque spindles and strong carbide or CBN cutting tools. Metal materials with aluminum and brass composition need distinct tool coating and feed rate parameters to circumvent tool degradation. Cooling systems play a vital role as these help to stop heat-related material warping.
Cutting Accuracy and Tolerance Levels: Precision at a Micron Scale
Gears demand extreme accuracy. A 5-micron deviation of 0.005mm results in operational failure for high-performance scenarios. Advanced CNC equipment contains servo systems. These operate in closed loops with laser calibration functions for precise tolerancing. Equipment consisting of ball screw drives and direct-drive motors accomplishes backlash reduction by maintaining smooth precision throughout each gear tooth cut.
Production Volume and Automation: Efficiency vs. Customization
Does your business need to produce tens of thousands of gears daily, together with specialized yet limited production runs? The requirements for CNC machines used by high-volume manufacturers include automatic tool changers (ATC) combined with robotic loading/unloading systems. Hybrid machines that contain hobbing and grinding functionality minimize the number of manufacturing setups. The best option for making custom or prototype gears involves flexible machines with quick programming capabilities and multi-dimensional functionality.
Machine Rigidity and Stability: Controlling Vibration for Perfect Gears
Excessive machine vibration causes cutting tools to lose their performance potential. Vibrations get absorbed by a rigid machine frame. It maintains exact cutting precision through its cast-iron or polymer composite material construction. Highly precise linear guides, combined with reinforced gantries, function to stop unwanted deflection because it represents a key requirement in machining fine-pitch or micro gears.
Software and Control System: The Brain Behind the Machine
Software running the machines is equivalent to hardware. Because it determines the outcome in CNC gear cutting operations. New machines use artificial intelligence (AI) control systems with real-time measurement capabilities and automated predictive maintenance algorithms. Programming tasks for generating complex gear profiles become easier through advanced CAD/CAM software solutions. Furthermore, IoT connectivity enables machines to perform remote diagnostics, which in turn decreases machine downtime and raises operational effectiveness.
Final Verdict
CNC machine gear cutting produces highly accurate gears of superior quality. Each production method, from milling to hobbing and shaping and grinding, allows the manufacturing of gears that propel industrial operations forward. The automotive sector, as well as aerospace and heavy machinery, depends on these gears for dependable operation under all demanding situations.
When selecting a CNC gear cutting machine, you must decide between advanced models while still considering their match to particular requirements regarding precision and efficiency and durability standards. A successful investment in CNC gear machines requires careful consideration of material selection, machine hardness, automation capabilities, and precision control systems.
Wandel Machinery, a leader in innovative construction equipment, is revolutionizing the tile-cutting industry with its latest launch: the 3000W brushless motor tile cutting machine. Showcasing models like the QXZ-ZD-1600, QX-1000, GT-AT-1200, QZ-1000, and the acclaimed QX Series & QXZ Series at their booth, Wandel Machinery combines power, precision, and energy efficiency to meet the demands of modern construction projects.
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