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A Quick Guide to Linear Shafts

A Quick Guide to Linear Shafts

October 15, 2022

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A Quick Guide to Linear Shafts

Guide to Linear Shafts

A linear shaft is a metal rod that moves large objects or assemblies on a linear plane. These precision parts are used in a variety of industries, and they provide smooth and precise movement. You’ll find linear shafts in things like MRI machines, vehicle seats that move back and forth, and printing and packaging machines. The linear shaft is the part that provides support and keeps everything in the proper place as they move.

There are a few different types of linear shafts. Most of these are made with hard metals and have the strength required to support 100s or 1,000s of pounds.

This guide to linear shafts will give you some info about how the shafts are manufactured, the various types, and their use cases.

What is a linear shaft?

A linear shaft is a metal rod that supports linear motion (moving in a straight line). Usually this is a sliding or gliding motion. The shaft is mounted onto the application and doesn’t move, but rather supports the parts and components that are moving. In the case of powered mechanisms, the shaft works with an actuator, support rails, or bushings and ball bearings for manual movements.

The shaft is the piece that’s usually bearing most of the weight, so they’re manufactured with durable metals that can withstand the weight and resistant to wear over time from the other parts sliding back and forth.

Linear Shaft

Types of linear shafts

The general shape of the linear shaft is the same—a smooth metal rod. There are slight variations, depending on the specific use of the rod.

Many linear rods are solid metal to provide the necessary tensile strength. They can be hollow or have a key slot that allows wiring or liquid to move through them. 

Other features are added to the ends of the rods. Inner and outer threading, stepped and chamfered ends, or holes can be added to the ends for mounting purposes.

Types of Linear Shafts

Common applications

Linear shafts are used in just about anything that moves or slides back and forth with precision. You won’t find these shafts in your sliding kitchen drawers, because precise movement isn’t required. 

Here are a few of the real-world applications:

Aerospace industry: Linear shafts are used to move seats and to slide out stairs and ramps.

Automotive industry: Linear shafts are used for electric seat adjustment.

Medical industry: Linear shafts are used for many different machines like MRI machines, scan machines, operating tables, and more. 

Manufacturing industry: Linear shafts are used for printers and packaging machines, and sliding tables.

Linear shafts can only be mounted and supported from each end, because the other parts are moving up and down the shaft. In cases where longer distances are required, and more weight is being moved, a rail system is preferred. The rail system can be supported at multiple points without interrupting the movement because the moving parts only use the top part of the rail.

How are shafts machined?

To provide smooth back and forth movements, the shafts need to be machined with precision, and have a smooth surface finish. The most common machining method is CNC turning or lathe machine.

These machines hold the raw bar stock in a spindle and rotate it at high speeds. A cutting tool works to remove the material to the specified part design. CNC turning machines are the most efficient type of machine for making cylindrical parts with precise measurements like linear shafts. 

In most cases, the milling machine can form all of the part features at the same time, so no secondary machining is required. Depending on the surface roughness requirements, the shafts might be polished after machining to improve the smoothness.

Materials and coatings

The primary function of linear shafts is to support weight and provide smooth movements. 

The most common materials used are stainless steel alloys. Stainless steel provides great strength and resistance to wear and corrosion. 304, 316, and 316L stainless steel alloys are the most commonly used because they provide excellent corrosion resistance. 316 and 316L are preferred for applications in food processing, semiconductor, and medical industries. 440 stainless steel is also great for high pressure applications.

In cases where lower tensile strength is needed, aluminum alloys are used. Aluminum is much lighter, less expensive, and still has good corrosion resistance. Most aluminum shafts are anodized to increase durability. 

When rust and corrosion is less of a concern, carbon steel is used. This is much less expensive and offers similar tensile strength as stainless steel. Carbon steel can also be plated or heat treated to improve corrosion resistance.

Order custom linear shafts

Spex offers a large selection of custom precision machined parts for whatever your project needs. We are an ISO 9001:2015 certified company, and our team specializes in precision machining and supply chain efficiency. Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

Reach out to our team to get a quote for your next project.

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Talk with one of our team members to get a quote for precision linear shafts.

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Different Types of Precision Pins

Different Types of Precision Pins

September 1, 2022

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Different Types of Precision Pins

Types Of Precision Pins

Pins are used in millions of consumer and industrial products. Pins are one type of precision fastener. They come in an unlimited variety of materials, shapes, and sizes and are commonly used to align and hold parts and assemblies together. 

Precision pins are machined to hold two components together when a threaded screw or bolt shouldn’t or can’t be used. Most pins are semi-permanent, which means they can be removed and replaced fairly easily.

Types of precision pins

Pins are a simple part that’s usually cylindrical and without threading. Different types of pins are used in different capacities.

Types of Precision Pins (1)

Dowel Pins: Precision dowel pins are short cylinders that keep multiple components in proper alignment. Dowel pins are usually solid metal and can be machined using stainless steel, brass, carbon steel, and nearly every other metal. You’ll find dowel pins used in furniture assemblies, but wooden dowel pins usually aren’t as precise as metal pins. Dowel pins are available in high-precision tapered, slotted, spiraled, stepped, and grooved designs.

Spring Pins: A spring pin, or rolled pin, is a hollow or coiled cylinder of metal—usually rolled steel. Spring pins are slightly larger than the hole they’re used for to provide a snug fit, and a chamfered edge on one or both ends to help facilitate starting the pin into the hole.

Grooved Pins: Grooved pins are solid dowel pins that have grooves running down lengthwise. Grooved pins don’t have less material. Instead, the grooves are swaged, which displaces material and increases the diameter of the pin. The grooves close when the pin is forced into a hole, which gives grooved pins more elasticity than standard dowel pins. Similar to spring pins, there is a pilot or taper on the end to help get the pin started. 

Locating Pins: There are dozens of different styles of locating pins that can be used in different situations. Locating pins can be used to locate and align a workpiece on a fixture, or to align two pieces of a fixture.

Where are precision pins used?

You can find pins nearly everywhere. Since we’re focusing on pins with more precision dimensions, they’re most commonly used in the automotive, electronic, aerospace, and defense industries. When the right materials are used, precision pins provide a secure bond between two metal parts, and they can withstand a decent amount of pressure.

Precision pins need to be manufactured precisely and with care to fulfill their purposes.

These can be found in industries where high standards and tight tolerances are necessary. Precise machining is required for pins being used in the aerospace and automotive industries.

Other applications where you can find precision pins include electronics, mining tools, plumbing, and power distribution. The power distribution industries are some of the most common users of precision pins. This type of pin is used for shafts, male connector pins, mechanical applications, and more.

Common materials used

Because the pin is in constant contact with other metal parts, the material used for pins needs to be complementary to the surrounding materials. It’s also essential to consider the environmental circumstances of the assembly– if there’s going to be moisture or chemicals present, or constant temperature changes. 

Most pins are constructed with harder metals like steel, stainless steel, carbides, or superalloys like Monel or Hastelloy. Some applications may require softer materials. These materials are usually brass, aluminum, or mild steel.

Secondary processes are also used to improve the durability of the pins. It’s very common for pins to be galvanized, plated, heat treated, or anodized to increase the hardness and corrosion resistance of the metal.

How are precision pins manufactured?

There are many different ways to manufacture pins. Since most pins are ordered in large quantities, high volume machining methods like cold heading, spring pin machines, and Swiss screw machines are used.

The most common production process is called cold heading. Cold heading is the best way to manufacture high quantities of precision pins from a variety of metals.

The cold heading process starts with a long wire of metal, and then cuts the wire into smaller pieces called slugs. Then, the cold heading machine presses the slug into the desired shape. Depending on the specifications of the pin, there are one or multiple unique presses.

The cold heading machine uses a series of powerful hammer-like movements and dies to form the desired shape and dimensions. Since pins are a more simple shape than most parts, this process is more efficient than CNC machining. Cold heading allows rapid production of high quantities while maintaining tolerances within 50 microns (0.0002 inches).

For spring pins and rolled pins, a different type of machine is used. A spring pin machine takes a flat strip of metal and rolls the material into the desired pin shape, length, and thickness. This process is also ideal for high quantities and is relatively cheap compared to other machining processes.

Swiss screw machines are used to machine more complex precision pins. These machines specialize in making small, cylindrical shaped parts. The Swiss screw machine has exceptional precision, maintaining tolerances of ±0.005mm (0.0002in). This machining method is also efficient for high-volume orders because it can run automatically for hours without human involvement.

Order custom precision pins

Spex offers a large selection of custom precision pins and rollers for whatever your project needs. We are an ISO 9001:2015 certified company, and our team specializes in precision machining and supply chain efficiency. Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

Reach out to our team to get a quote for your next project.

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Types of Rivets: Learn About Different Rivets and Their Common Uses

Types of Rivets: Learn About Different Rivets and Their Common Uses

May 30, 2022

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Types of Rivets: Learn About Different Rivets and Their Common Uses

types of rivets

Rivets are a common type of fastener used to hold two or more parts together. Rivets are designed to be a more permanent faster, and out of all the different fasteners, rivets are most similar to nails. 

Rivets are used in many different mechanical operations, and have been for a long time. The concept is very simple, and in fact, the first rivets were used around 3,000 BC. Rivets were used to hold ancient tools together, like the head and handle of a hammer, and to attach a carrying handle to a jar.

The rivets used today are more precise and durable, but they have the same general design and purpose. Rivets can be used for lightweight purposes, and heavy duty machines like tanks or aircraft. 

How does a rivet work?

A rivet is similar to a nail, but they’re not exactly the same. Rivets usually don’t have threading, and they have a flat or rounded head. Unlike nails, rivets usually don’t have a sharp pointed end. Rivets also have a larger body, similar to a bolt.

When rivets are being used, a hole is drilled into the materials that the rivet is holding together. The hole drilled is slightly larger than the rivet. Then, the rivet is inserted, and the back end of the rivet is smashed or deformed so it’s larger than the hole drilled. This creates a tight connection between the two materials. And the rivet would need to break before the materials separate. 

Smaller rivets are installed with a handheld tool called a riveter or rivet gun. Larger industrial rivets, like the ones used for bridge construction work the same way. But, those need to be heated up before the end is smashed so it can be deformed.

How rivets work

What are the different types of rivets?

Rivets are a basic type of fastener, but there are some different types designed for specific uses. 

Solid rivets

Solid rivets are just what they sound like. They have a solid round body and either a flat or rounded head.

The rivet is inserted into the hole and the end is smashed with a hammer, or other squeezing tool. Depending on the size of the rivet, a lot of force can be required to deform the end so it stays in place. 

Solid rivets are the most secure and can bear the most weight and are the most reliable. They’re used for load bearing applications like building frames and bridges, Solid rivets are also used in aircraft, cranes, and other vehicles.

Tubular rivets

Again, tubular or hollow rivets are exactly what they sound like. They look the same as solid rivets, but the body is a partially or fully hollow tube. With these rivets, the tail end isn’t solid, which makes it much easier to deform. These rivets require about 25% of the force to secure compared to solid rivets. 

Countersunk rivets

Countersunk rivets or flat rivets are designed to not stick out once they’re installed. There’s a small hole for the rivet, and a slightly larger hole made for the head of the rivet. These are used to improve dynamics on vehicles, and on sliding tracks where something needs to slide over the rivet without hitting it. 

Split rivets

Split rivets have a split end. Usually there are two small legs on the end of the rivet that are spread apart to secure the rivet. These are commonly used with softer materials like drywall, leather, wood, or plastic. 

Blind rivets

Blind rivets are unique because they can be installed without accessing the other side of the rivet. These rivets are technically two different parts. The rivet has a pin that pulls out when it’s installed. The pin is pulled out and squishes the end of the rivet to secure it. Blind rivets are used in aircrafts, watercraft, and electronics. 

How are rivets manufactured?

There are two primary ways that rivets are manufactured.

Thinner rivers are made by cold forming. A round wire is fed into a machine and cut to the desired length. Then the piece of wire is punched into a dyes, or cutouts, to form the shape of the rivet. It takes a few different dyes to fully form the rivet body and head. But, this process all happens very quickly. Hundreds of rivets are made every minute, and they’re fairly accurate. 

Rivets can also be made using Swiss screw machines. This process is used for solid rivets, when stronger materials are needed, and when more precision is needed. Since rivets have a simple design, Swiss screw machines are still efficient and keep manufacturing costs low.

What materials are rivets made with?

Rivets are made with a wide variety of metals. The harder metals offer greater strength, but they also require more force to install the rivet. Softer metals like copper or brass can’t handle as much stress, but they’re easier to install. 

Rivets are commonly made with

  • Stainless steel
  • Steel
  • Aluminum
  • Copper
  • Brass

Spex is a precision machine shop located in Rochester, New York. We manufacture a wide range of precision parts and fasteners including rivets. If you need rivets, or other precision parts, fill out the form to connect with our team.

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Different Types of Lock Nuts

Different Types of Lock Nuts

May 15, 2022

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Different Types of Lock Nuts

Different Types of Lock Nuts

Lock nuts are a special part that’s designed to hold parts and assemblies together. These parts are built to be used for long periods of time.

Spex machines different types of precision lock nuts for various industries and uses. Today we’ll share some info about how lock nuts are manufactured and used.

What are Lock Nuts?

A lock nut is a type of nut that’s designed to not loosen over time. There are different methods to keep the nut secure, including adhesive, pins, and features that increase friction. Some lock nuts are designed for single use, making them less effective or unusable after they’re removed.

In general, nuts are used for assemblies that need to be disassembled. That’s helpful when different parts need to be cleaned or to perform regular maintenance. Lock nuts are more difficult to assemble and disassemble, but they provide greater security and reduce the risk of parts coming loose. 

Lock nuts are commonly used for assemblies where there are moving parts or vibration, which causes other nuts to loosen over time.

How do lock nuts work?

There are a few different ways that a lock nut stays secure. The three common ways are adhesive, friction, and pins.

Adhesive

The most common type of lock nut has some type of adhesive. This could be a type of glue, or a nylon ring that creates a tight seal on the bolt. 

Friction

Some lock nuts have specific features that increase the friction. Some have grooves on the bottom of the nut, which increases friction with the surface that the lock nut is touching. Other lock nuts have specific threading that increases the friction between the nut and bolt. Both of these designs make it more difficult for the nut to come loose.

Pins

Lock nuts that use pins have a hole or groove cut into them. Once the nut is tightened onto the bolt, a pin is inserted through a hole in the nut and bolt to prevent it from spinning off. A cotter pin can also be added on top of a lock nut with grooves cut in the top.

5 Different Types of Lock Nuts

5 Different Types of Lock Nuts

1. Nylon insert lock nuts

These lock nuts have a nylon ring or patch on the inside threading of the nut. When they’re threaded onto the bolt, the nylon creates a seal. These nuts are subject to high temperatures which could melt the nylon, and they require more torque to assemble. 

2. Hex jam nuts

Jam nuts are actually two nuts that are used on top of each other. The second nut is jammed on top of the first one, preventing it from spinning off the bolt. 

3. Center lock nut

A center lock nut has a hold drilled into the center of it. Once the nut is tightened, a punch is used to distort the threading on the bolt, which prevents the nut from loosening. 

4. Serrated Flange lock nut

The serrated lock nut has grooves on the back side of the nut. These nuts are usually used against sheet metal. The grooves on the back of the nut rub against the surface and prevent it from backing out.

5. Castellated nut

A castellated nut has grooves on the top, which look similar to the top of a castle. These lock nuts are used with a bolt that has a hole drilled in it. Then, a pin is inserted through the top of the nut and bolt to secure it in place.

What are lock nuts made of?

Because most lock nuts are used for heavy-duty and industrial applications where strength is a priority, most are made with stainless steel or mild steel. Stainless steel alloys are the most common material because it’s strong and resistant to corrosion. Zinc and brass locking nuts are also fairly common. 

In cases that require less strength, nylon or plastic lock nuts are popular because they’re less expensive to manufacture and lightweight.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project. 

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Custom Dowel Pin Manufacturing​

Custom Dowel Pin Manufacturing​

February 2, 2022

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Custom Dowel Pin Manufacturing

Custom Dowel Pin Manufacturing_

Dowel pins are short cylindrical parts that are used to align or join two or more parts. Wooden dowel pins are commonly used to hold furniture together. Metal and plastic dowel pins with custom diameters and lengths are found in machinery, vehicles, and consumer goods.

Pins are a type of precision fastener and they’re made with any type of material and available in every diameter and length. Spex uses different machining processes to manufacture a wide variety of custom dowel pins. In this post, we’ll explain more about precision dowel pins and their uses.

Different types of pins

Pins usually serve a similar function as screws or bolts, but pins are unthreaded. Instead of threading, pins use different methods of staying in place and hold parts together. Usually a custom pin has a specific diameter size that matches the parts it will hold together. The lengths are also machined to the part specifications.

The names of pins usually refers to the different features of the pin. A grooved pin for example, has grooves running along the length of the part which gives them more elasticity. A spring pin is a hollow pin that’s able to be compressed and expanded. A spring pin or roll pin is another hollow pin that’s made with rolled metal.

Types of Precision Pins (1)

Dowel pins are solid pins, and usually the most precise type of pin. These are also the most basic type of pins and don’t have the secondary features that other precision pins have. Because dowel pins are more precise, they can also be more difficult to insert and remove.

One or both ends of the pin is chamfered to help align and inset the pin into the hole. Once it’s in place, a precision dowel pin provides a very tight seal and hold components together for a long time and withstand a good amount of pressure. Because dowel pins are headless, they can be more difficult to remove than a screw or bolt.

Stepped dowel pins are used when components with two different sized holes need to be connected. One half of the dowel pin will be smaller than the other end. The last common type of dowel pin is a pull dowel. These pins have a threaded hole so a screw can be inserted to remove the pin more easily.

Common uses and materials used for dowel pins

Dowel pins are one of the simplest types of fasteners available and can be the perfect solution for many different machines. Pins in general have been used for thousands of years. Of course, modern machining technology has improved and expanded the use of precision metal pins. Our machines can mass produce dowel pins with extreme precision.

Because they’re incredibly versatile, simple, and cost efficient, pins are used in thousands of different applications.

Dowel pins are commonly used in machinery to keep components properly aligned. Solid pins usually do a much better job at maintaining alignment compared to screws. Metal dowel pins retain their physical dimensions, meaning they won’t easily wear down or lose their shape. This makes metal dowel pins ideal for machines where precision is required.

Dowel pins are also used in the automotive, medical, aerospace, and military industries.

You’ll find wooden dowel pins in your furniture, but using metals offers much greater precision and strength. At Spex, our Swiss lathes and other machines can produce custom dowel pins within a 0.0001″ tolerance.

Custom dowel pins can be made of various materials. Each material has different advantages and the best choice is dependent on how the is being used. Some industries require specific alloys to be used to meet strength requirements. The most common materials include:

  • Aluminum
  • Carbon steel
  • Stainless steel
  • Titanium
  • Nickel alloys
  • Brass

In some instances, plastics or polycarbonates will be used for pins in electronics or in components that require less strength.

If you’re not sure which material to use for your custom dowel pins, our team can help you decide which one is best for your unique application.

Get a quote for custom dowel pins

Are you looking for a dowel pin manufacturer? 

Spex is an industry leader in manufacturing precision fasteners and pins. We are an ISO 9001:2015 certified organization, which means we use the highest industry standards for manufacturing parts. Our vast machining capabilities allow us to produce large quantities of parts that meet the tight tolerances that are often needed.

We have decades of precision manufacturing, customer satisfaction, and serve many industries around the world

Reach out to get a quote for your next project.

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What Are Precision Spacers Used For?

What Are Precision Spacers Used For?

November 17, 2021

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What Are Precision Spacers Used For?

What Are Precision Spacers Used For

Precision metal spacers are parts used to fill a gap between two objects or surfaces. Spacers can be made using virtually any material, including rubber, hard plastics, and metals. These parts are commonly round and unthreaded to be used on bolts and rods. But, spacers can be threaded or partially threaded, as well as different shapes.

In this post, we’ll explain what precision spacers are commonly used for, and how you can order custom spacers for your next project.

Common applications

Spacers are found in many different machines and vehicles. Spacers can help reduce friction and vibration. 

Spacers are simple parts, which allows them to be used in a wide range of industries. You’ll find spacers everywhere, from orthodontics to high-pressure tools and machinery. Many vehicles and engines use spacers that require tight tolerances, so high-precision metal spacers are most commonly found in the aerospace, agricultural, automotive, and electrical industries.

Examples of precision spacers

Shims vs Washers vs Spacers

Shims, washers, and spacers are similar parts, so it can be difficult to figure out exactly what you need. There are a few key differences between these three parts.

Shims are usually a thinner piece that is used to create space between two surfaces. Shims typically help create a seal, or in cases where there needs to be a tight tolerance. Different size shims can be used when the two surfaces start to wear down. These are usually thinner compared to spacers and washers.

Washers are used to distribute a load. Washers can also be used to lock a nut and bolt together, and come in different shapes. Washers are primarily used with screws and bolts.

Spacers are similar to washers, but usually more precise. Spacers are also longer than most washers and shims to create space or add clearance.

Common materials used

Spacers can be made from virtually any material, depending on the application and surrounding parts.

Rubber spacers are used when you need to create a buffer between two parts. The rubber reduces the impact of moving parts. This reduces vibrations and provides an effective seal.

Nylon spacers are harder compared to rubber. These are used to adjust the space between two objects while providing vibration and corrosion resistance. Nylon is lightweight, nonmagnetic, and fairly durable.

Aluminum spacers are lightweight, easily machinable, and corrosion-resistant. Aluminum isn’t as strong as some other choices. It’s a cost-effective solution that’s commonly used in various aerospace applications. In addition, aluminum is an environmentally friendly choice due to its ease of recycling.

Copper spacers are a softer metal that can provide a vibration buffer while still offering some flexibility in applications where high rigidity might cause parts to crack or break. Copper and bronze are also conductive and used where electricity needs to flow between components.

Stainless steel spacers are used for strength and resistance to extreme temperatures and corrosive environments. Stainless steel is also visually appealing. It’s heavier compared to many other metals, but stainless steel can also be the least expensive option over the course of its lifetime.

Titanium spacers are often considered one of the highest quality metals available. It’s light, very strong, and resistant to corrosion.  However, titanium is one of the more expensive options, and less costly options are acceptable for most uses.

Spex manufactures precision spacers from any type of metal, and our team can help you choose the right material for your specific project.

How are metal spacers machined?

Most precision spacers are manufactured with a CNC turning machine. The CNC turning process is commonly used for cylindrical parts like shafts and spacers. 

After the machinist programs the machine with the specific part dimensions, the raw material is loaded into the machine. Then the material is spun around and moved towards the cutting piece to machine the desired shape and holes. 

The turning process is efficient and can produce high quantities of spacers with tight tolerances. For applications in the aerospace industry and defense industry, maintaining tight tolerances is crucial. The CNC turning process makes tight tolerances achievable and repeatable at low costs.

Order custom precision spacers

Spex offers a limitless selection of custom precision spacers for whatever your project requires. Our custom machined parts are available in an array of different materials and finishes and are manufactured to meet all quantity needs. Our team is available to help you choose the best option and work to optimize your supply chain needs.

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Intro to Custom Manifolds

Intro to Custom Manifolds

October 4, 2021

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Intro To Custom Manifolds

Intro To Custom Manifolds_

Manifolds are precision machined parts used to distribute gasses and liquids within a system. Manifolds offer a simple and efficient design that’s used in vehicles, measurement tools, pressure regulators, and more.

In this article, we’ll share what manifolds are used for, the materials used to machine them, and the various types of manifolds.

Brief Overview of Manifolds

Manifolds are typically used to disburse a common supply of air, gasses, or fluids to multiple locations within an assembly. There is usually one input and multiple outputs. Manifolds are typically made from aluminum, brass, or steel, and they range from two-port designs to larger twenty-port manifolds. Manifolds usually have either tapered or straight mechanical pipe threads which connect the inputs and outputs.

The manifolds used for air typically look different than ones used for fluids. The specific materials used, designs, and measurements vary depending on what the parts are being used for, but the primary job of a manifold remains the same. 

These parts are used in a number of industries, including: 

  • Transportation
  • Measurement
  • Valve and Controls
  • Machine Tools
Here are a few examples of what different custom manifolds can look like:
Examples of manifolds

What are manifolds used for?

As we mentioned before, a manifold is used to distribute gas or liquids. The simple design of manifolds helps save space, reduce costs, and increase efficiency.

Metal manifolds also provide a tight seal which decreases the chances of oil and air leaks, and provide a shorter flow path that helps maintain pressure in the system.

The medical industry uses manifolds in blood analyzers, lab equipment, and dialysis machines. The agriculture industry uses them in planters, tractors, and harvesters. Industrial industries use manifolds on forklifts and manufacturing equipment. The oil and gas industry uses them with oil exploration, hydraulic fracturing, and extraction machinery. The ability to easily regulate fluid and airflow allows machined manifolds to be used nearly anywhere.

Spex primarily machines precision manifolds for measurement tools, vehicles, and machine tools.

Types of manifolds

There are a few different types of manifolds that each have unique advantages and use cases. The type that will work best for your system is based on several factors, such as how much space is available, the intended function of the system, budget, and more.

Gas manifold

A gas or pneumatic manifold is used to eliminate a large portion of tubing in a system, which results in minimal system complexity, quicker dismantling, less leakage, and lower maintenance costs.

You’ve likely seen a type of gas manifold if you’ve used an air compressor before. Gas manifolds are used to connect a single source of air and safely distribute it across multiple channels. For example, a manifold lets you connect multiple air-powered tools to a single air compressor.

The manifold provides a safe and cost-effective connection from a gas supply line to high-pressure gas cylinders, increasing storage capacity and flow rate. The manifold also ensures gas purity by eliminating the need of a regulator directly onto a gas cylinder valve.

Pneumatic manifolds are made of brass, aluminum, stainless steel, and sometimes nylon polycarbonates, depending on the pressure requirements.

Hydraulic manifold

A hydraulic or liquid manifold is used to fluid flow between pumps and actuators and other components in a hydraulic system. The manifold allows operators to control how much fluid flows between components in a hydraulic machine.

For example, in a lot of construction machinery, like a backhoe or forklift, the hydraulic arm of the machine is controlled using levers in the cab. The levers act as switches for the manifold block, which transmits the fluid where it’s needed.

There are two distinct types of hydraulic manifold blocks: mono-block and modular block designs.

A mono-block design is a hydraulic manifold machined out of a single piece of steel or aluminum, or pieced together from layers of metal. The valves and channels are milled before the layers are put together. In the case of a single piece of steel being used, the machining needs to be done carefully to avoid splitting or damaging the block. Once the manifold has been assembled, the entire thing is sealed, creating one solid, watertight part.

The main advantage of a modular manifold is the ability to change configurations. These are usually made up of smaller components that can be added to or removed from the system. Different plates and valves can be added and removed from the system to achieve the desired result, making these systems much more adaptable than the mono-block.

Block and bleed manifold

A block and bleed manifold is a type of hydraulic manifold that combines a block valve, usually ball valves, and a bleed valve, into one component for interface with other components (pressure measurement transmitters, gauges, switches, etc.) of a hydraulic system.

The purpose of the block and bleed manifold is to isolate or block the flow of fluid in the system so the fluid coming into the manifold doesn’t reach other components of the system that are downstream. Then they bleed off or vent the remaining fluid from the system on the downstream side of the manifold.

Materials used for manifolds

Almost any type of metal can be machined into a manifold, but the three most common materials used are stainless steel, aluminum, and brass. When selecting the right metal for your project, you’ll need to consider the cost, strength, resistance to wear, and pressure.

The type of material used depends on the type of air or fluid flowing throughout the system it’s used in. Here are some examples of when you might use the various metals:

Stainless steel

Stainless steel manifolds are going to be the more durable option. In a high-pressure system (over 3,500 psi) using stainless steel rather than aluminum is necessary. You might also use stainless steel for the aesthetic look if the manifold will be visible.

The drawbacks of stainless steel are that it’s a more expensive material, and more difficult to machine which increases costs.

Aluminum

Aluminum manifolds are lightweight, easy to machine, and less costly overall. Typically aluminum is anodized which provides a level of protection against corrosion. For larger hydraulic manifolds, aluminum is a great choice because it’s easier and faster to machine the inlets and outlets of the manifold. Aluminum is also about 1/3 of the weight of stainless steel, if weight is a factor.

Brass

Since most plumbing parts are made of brass, using a brass manifold can prevent leaks. When the temperature changes as water moves through the manifold, the same material has the same expansion rate. Mixing a steel manifold with brass plumbing parts could lead to more leaks if the brass expands more or less than the steel.

Brass is also a durable material, heat resistant, and softer which makes installation easier.

You can reach out to our team if you need help deciding which material is best for your project.

Spex has the equipment and expertise to produce custom manifolds that fit your exact design. Our staff will work with your engineers to develop the most cost-effective manifold to meet your needs.

Order Custom Manifolds

Talk with one of our team members if you have any questions about ordering precision custom manifolds.

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Types of Precision Fasteners

Types of Precision Fasteners

September 12, 2021

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Types of Precision Fasteners

Types of precision fasteners

Fastener is a general term for a part that holds two or more objects together. You see all different types of fasteners everywhere in the world, and they come in every shape and size imaginable.

Screws, bolts, nails, rivets, and anchors are all fasteners used in different applications. Each type of fastener has unique attributes that allow systems to work properly. For example, the fasteners in your air conditioning unit are different from the ones you’ll find in a cruise ship.

In this article, we’ll explain how different types of fasteners are used, and the types of material fasteners are made with.

What is a fastener?

Fasteners have one primary job: hold multiple pieces together. Things like velcro, glue, or tape have the same role, but those are not fasteners. Fasteners are typically made of metal so they can withstand the pressure. Hard plastics are used in some instances, but the majority of fasteners are metal.

Fasteners are also not designed for a permanent joint. You can usually find that screws attach the door handle to the door. The screws provide a strong connection and allow you to remove the handle from the door whenever you need to without damaging anything.

Fasteners such as nails or rivets are more difficult to disassemble, but they’re not as permanent compared to welding. You can remove nails and rivets with little impact on the components they were holding together.

Here are a few different types of fasteners that we manufacture, and their characteristics:

Screws

These are the most common type of fasteners used in the world. A screw is extremely versatile and used everywhere. You could look around your home or office and find hundreds of screws. Screws are easy to install and uninstall, and they can be made with highly precise measurements. You’ll find very tiny screws inside a watch, and huge screws inside wind turbines.

  • Wood screws have coarse threads and a tapered head.
  • Sheet metal screws have sharper threads for connecting metal to other materials.
  • Machine screws have a uniform thickness and don’t taper off at the bottom.
  • MDF screws can self-tap without splitting the material.

Bolts

Bolts are similar to screws but are usually bigger and stronger. Bolts work together with washers and nuts to join multiple pieces together. Unlike screws, you will need access to both ends of the bolt to attach the nut. The washer helps to spread the load over a larger surface area, which reduces the wear and tear as well as the loosening of your bolt over time while the nut secures the bolt in place.

Like screws, bolts come in many sizes and types. They’re also usable with several materials ranging from metal and wood to concrete. Compared to screws, bolts are easier to remove.

  • Carriage bolts often have a domed or countersunk head with a square component under the head to keep the bolt from spinning while tightening the nut.
  • Flange bolts include a circular flange beneath the head for distributing loads evenly.
  • Plow bolts are for heavy-duty applications, such as construction equipment.
  • Hex-head bolts are six-sided with machine threads.
  • Square-head bolts have square heads, offering an easier grip for wrenches.
  • Allen bolts have a hexagonal socket for use with Allen wrenches.

Nuts

Nuts are used to secure the bolt in place. Along with washers and spacers, nuts help evenly distribute the weight or pressure on the bolt. Nuts are available in various shapes, sizes, and materials. It’s best to use the same material for a nut and bolt to avoid one wearing down before the other. Self-locking nuts can have a nylon ring to form a tighter lock and avoid loosening over time, or they can have a slot to place a pin that prevents movement.

  • Coupling nuts are hex-shaped and join two male threads together.
  • Flange nuts have a wide, serrated flange on one end that serves a similar function as a washer but without any added movement.
  • Hex nuts are the most common variety, featuring a hex shape and internal threads.
  • Lock nuts include designs to prevent loosening due to vibrations.
  • Slotted nuts have sections cut out to create a locking mechanism with the help of a cotter pin.
  • Square nuts feature a square shape for greater surface area.

Clevises

A clevis fastener is a two-piece fastener system consisting of a clevis and a clevis pin. The clevis is a U-shaped part that has holes at the end of each end to accept the clevis pin. The clevis pin is similar to a bolt, but is either partially threaded or is unthreaded with a cross-hole for a split pin.

Anchors

Anchors serve a similar function to a boat’s anchor. An anchor is similar to a bolt with no head, and embeds itself into a hole. Generally, people use anchors to connect something to a material like drywall or concrete. They embed themselves in the material and hold the object in place.

Different uses for fasteners

Fasteners are used in nearly every industry since the sizes and materials are limitless. 

You can find fasteners around your house used to hang photos, attach the door to your cabinet, or hold the legs onto your chair. These types of fasteners need to be the right size to work properly, but they’re not as precise.

The fasteners used in the medical field, automotive industry, and aerospace industry are held to higher standards. The parts used in a vehicle are under significantly more pressure compared to the screw used to attach cabinet handles. For these projects, the parts have tighter tolerances and stronger materials are used.

Fastener materials and finishing

The majority of fasteners are made from a hard metal alloy such as steel, stainless steel, or a superalloy like Inconel. Spex uses these materials to machine precision fasteners:

  • Steel
  • Stainless Steel
  • Carbon Steel
  • Monel
  • Inconel
  • Hastelloy
  • Aluminum
  • Brass

To do their job, fasteners need to have a high level of strength and resist high stress levels and temperatures. In some cases, a coating is applied to the parts to increase their corrosion resistance and longevity.

Coating and plating techniques increase fastener capabilities by helping to regulate torque pressure, lowering thread resistance, and enhancing durability. Fasteners can be plated with nickel, chromium, or be heat-treated to increase strength.

When you’re choosing which material is best, numerous factors such as environmental circumstances, corrosive elements, physical stress requirements, and overall structural stability, will influence material effectiveness. It’s essential to pick the best material and grade of metal for your specific project.

Order custom fasteners

We’re ready to answer any questions you have about ordering custom precision fasteners.

Our machining capabilities extend far further than what you might find on the shelf at your local hardware store. And we can promise you that our team will provide an excellent experience from start to finish.

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Using Custom High-Strength Bolts

Using Custom High-Strength Bolts

September 5, 2021

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Using Custom High-Strength Bolts

Using Custom High-Strength Bolts

Nuts and bolts have been used to hold things together for hundreds of years. You can walk into any hardware store and find hundreds of bolts of various lengths, diameters, materials, and shapes.

Bolts are a unique type of part because they allow you to assemble and disassemble components quickly and easily, compared to screws and rivets which provide a more permanent solution.

Understanding how bolts work in different applications and ordering what you need can mean the difference between your project being successful or falling short. This article discusses the use of bolts, different materials, and why high-strength bolts are used.

What are bolts used for?

When compared with other types of fasteners, nuts and bolts have the advantage that they can be disassembled whenever needed. If you have a system that needs to be taken apart for maintenance or repairs, bolts make your life much easier. Other fasteners such as rivets are designed for permanent installation.

Bolts also offer a much stronger connection compared to nails or screws. 

There are many different types of bolts, and each has different characteristics that make them usable across a wide range of industries. 

Here are a few types of bolts that are commonly used:

Types of bolts
  • Carriage Bolts: This is a type of self-locking bolt that affords a level of security by using a rounded head, which means you can only remove or loosen these bolts from the nut side.
  • Double End Bolts: These are also called stud bolts and feature a threaded portion on both ends of the bolt without a traditional head.
  • Flange Bolts: These contain a washer-like surface or flange beneath the head of these fasteners that increases the surface area of the clamping load. This reduces potential damage to the surface where these fasteners will mate. Flange bolts are often used in plumbing and automotive assemblies.
  • Shoulder Bolts: These are also called stripper bolts, they have a threaded bolt section of smaller diameter than the shoulder of the bolt (the section of the bolt between the head and the beginning of the threaded portion). Shoulder bolts are useful for functioning as a shaft or axle that can contain a rotating part, such as a bearing or a bushing.
  • Socket Head Bolts: These bolts feature a recessed head that is tightened using an Allen wrench or hex socket tool. The head style of these bolts can vary from a cylindrical profile to a flat-head countersunk style to a domed button head design, depending on the desired use. A deeper recessed Allen socket head allows for increased torque to be applied to the bolt while minimizing the risk of stripping or damaging the head.

What's the best material to use?

ASTM/SAE grade bolts can be fabricated from a number of material choices. These materials are the most common for high-strength bolts:

  • Low carbon steel
  • Medium carbon steel
  • Low carbon martensite steel
  • Weathering steel
  • Alloy steel
  • Medium carbon alloy steel

Bolts come in many varieties, such as T-Head or T-Slot bolts, and can be produced from a wide range of materials, but steel is the most common material used for high-strength applications.

In some cases, bolts will be plated with zinc or galvanized to increase the corrosion resistance. Zinc is the most common coating used today because it offers a decent level of corrosion resistance at an affordable price. Galvanized coatings offer a greater degree of resistance and are typically used where parts are exposed to moisture or salt, such as coastal areas.

How strong do structural bolts need to be?

High-strength bolts are made to withstand high amounts of pressure. A typical range for proof strength for steel is 50 to 100 kpsi (pound force per square inch). For example, a bolt with a 1 square inch cross-sectional area of steel can hold up to 50,000 to 100,000 pounds.

How is the strength tested?

The American Society for Testing Materials (ASTM) sets most of the standards for bolts in the U.S., including dimensions, materials, and finishing. A bolt’s overall mechanical strength is measured by the amount of pressure at which it breaks, while the yield strength is the level at which it bends or deforms.

Although the overall, or tensile, strength is always higher than the yield strength, for a machine to run properly the bolts should be kept under the yield level. Bolts that have a wide gap between their tensile and yield strength are considered flexible and will stretch further before breaking.

Steel bolts are graded according to newtons per millimeter squared for bolt tensile strength as compared to yield strength. For example, a steel bolt with a rating of 5.5 will provide roughly 500 n/mm2 (72.5 kpsi) of bolt tensile strength and approximately 400 n/mm2 (58 kpsi) of yield strength.

The higher the tensile strength, the tighter the bolt joint is, and the more torque the bolt can handle. The SAE (Society of Automotive Engineers) assigns bolts seven different grades, between 2 and 8.

A grade 8 bolt is the highest grade SAE bolt. Grade 8 bolts have a minimum tensile strength of 150 kpsi. Other bolt materials, such as stainless steel, alloys, and composite materials are rated in a similar fashion.

Grade 9 structural bolts are one the strongest structural bolts used today. A grade 9 bolt has a tensile strength of 180 kpsi. These bolts are ideal for heavy-duty applications and are often used in heavy machinery such as bulldozers. These bolts are considerably stronger than their grade 8 counterparts and are also more resistant to corrosive elements since they’re made with yellow zinc chromate.

How does threading impact the strength?

When ordering custom bolts, you’ll also need to consider the threading. Fine threaded fasteners are a better choice when specific measurements are required because the nut can be tightened closer.

Fine threads also provide greater tensile strength, since there is less material removed to make the threads. The shallow pitch of fine threads makes them much less susceptible to loosening from vibrations. Maintains joint tightness and clamping force better due to the smaller helix angle of the thread. Aerospace applications generally use fine thread fasteners due to their increased strength.

Larger threads are less susceptible to being nicked or damaged, so they do not have to be “handled with care” as much as fine threads. Coarse threads are much less likely to experience thread galling than fine threads. Larger thread allowances accommodate thicker plating, coatings and are therefore less likely to seize in corrosion-prone applications.

Order custom bolts for your next project

Do you need high-strength bolts for your project?

Spex manufactures made-to-order bolts that are machined to your exact specifications. We machine a wide range of materials, including steel, stainless steel, carbon steel, and superalloys like Monel, Inconel, and Hastelloy. We also supply plated bolts that have higher corrosion resistance for harsh environments.

Contact our team to get started on your next project.

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Talk with one of our team members to order precision metal parts.

We would love to hear from you! Please fill out this form and we will get in touch with you shortly.
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Phone: (585) 467-0520

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Office:
85 Excel Drive
Rochester, NY 14621

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