The Alternative
to Spinning, Wrap & Weld,
Supplemental Annealing
Some products simply cannot afford to fail. Ever. Like the breathing
tanks used by firefighters and miners. The missiles deployed by
our military. Or the brake system filter cases used by automobile
manufactures. In applications where product performance is mission
critical, commercial, military and aerospace companies need technology
they can rely on to manufacture deep-drawn cylindrical product
components that deliver superior product integrity and optimal
performance results. Every time.
But the fact is, many conventional production alternatives—like
impact, spinning and supplemental annealing—fall far short
when it comes to producing some failsafe, mission-critical parts.
These traditional processes cannot consistently deliver reliable
results for certain applications. They often use more raw materials
than product specifications require, adding to the overall cost
and weight of products. And they can make assembly of finished
products difficult. In instances when product characteristics can
mean the difference between success or failure—or even life
or death— the imperfections inherent in traditional processes
beg the need for a more advanced manufacturing alternative.
Reversing the process for better results.
Deep draw technology originated as a practical option for manufacturing
unique parts once considered too difficult or too costly to
produce through conventional methods. Through a virtually flawless
manufacturing
process, deep draw technology creates complex small, medium
and large cylindrical shells, tubes and other shapes requiring
close
tolerances.
Providing more reliable results than conventional alternatives
such as spinning, wrap and weld, supplemental
annealing.
In
addition to the cost advantages, deep draw technology results in
refined, highly calibrated products with tolerances in the thousandths—and
the accuracy is repeatable via highvolume, high-speed manufacturing.
Because the process allows for multiple wall thickness and diameters
in a single part, there is no need to weld or otherwise connect
separate product components to achieve the appropriate product
shape and dimensions. Thus, vulnerable interfaces in the final
product are eliminated, resulting in a product that performs more
reliably in the field—an especially significant advantage
in mission-critical applications. To further improve product quality,
deep draw technology relies on a controlled movement process. Typically,
when metal is shaped and formed, the material grains are scattered
and the integrity of the material structure is compromised. However,
the controlled movement process uses optimum speed to enhance the
efficiency of the process while maximizing material grain alignment
in the final product, translating into a higher quality product
produced as quickly as possible. The deep draw process also results
in a better finish than specified by most product designers. With
deep draw, the finish is typically 63 micro-inches or less, lending
a smooth, mirrorlike luster to the final part. Traditional processes,
such as spinning, wrap and weld and supplemental annealing, must
employ secondary operations to achieve the same quality finish.
In addition to the aesthetic advantages, the quality finish allows
for the direct application of sealing aspects such as O-rings and
gaskets during final product assembly, further eliminating secondary
operations and providing an excellent, leak-proof seal that stands
up to harsh field conditions.
Eliminating costly secondary manufacturing steps.
The Buckeye
Shapeform deep draw process is actually a reverse draw. On the
primary draw, material is pulled or drawn through a ring, forming
a cup-shaped cylinder with uniform wall thickness. The cylinder
is simultaneously turned inside out, or reversed, thus combining
two draws in one operation and saving steps and time. Ironing is
also performed during the deep draw process, which allows sections
of the material to be ironed down to different wall thicknesses.
Once the part is drawn or shaped, the forming process begins. The
necking and expanding processes allow for the creation of multiple
diameters in a single part. Diameters can either be expanded or
reduced (necked) to create forms that more exactly match the product
engineer’s specifications. The process results in seamless,
one piece parts with multiple wall thickness and diameters created
through minimal operations. This eliminates the need to spend time
and money on assembling separate product components (which is necessary
with conventional processes) while also delivering significant
product benefits:
- The multiple wall thicknesses give strength
where it’s needed while reducing the amount of material
used in other areas of the product, eliminating the waste of
raw materials
and reducing the overall weight and cost of the product.
- The
multiple diameters simplify the assembly and positioning of
internal parts and O-rings.
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