Hydraulic Cylinder Manufacturing - Essay Example

Hydraulic Cylinder Manufacturing Materials for Manufacturing Piston Rod of Hydraulic Cylinders i. Hardened rod materials Whenever there is impact damage on the piston rod, dents and bruising occur. Consequently, there might be leakages, potential rod breakage or even contamination of rod fluid within the hydraulic cylinder. Advantages of hardened rod The hardened rod can guard the hydraulic cylinder against damage and causing dents. It is highly tensile with a hardened induction case. In addition, hardened rod materials also have plated alloy of carbon with polished finish. All these qualities give it the ability to protect hydraulic cylinder from causing dent and bruising. Disadvantage of hardened rod Hardened rod material may remain very expensive keeping cost of production high. Secondly, the rods have carbon plating making it slightly hazardous to the environment. Hardened rod materials Highly tensile ISO No. Hardened induction case ISO 6020/2 Have plated carbon alloy Have polished finish ii. Rod End Below Protection Hydraulic cylinders in their piston rods have gland seals. Such gland seals have high risk of failing prematurely in environments with molten metal spatter and abrasive dust. Rod End Bellows are materials favorite for protecting exposed rod surfaces subjected to hardening Advantages of Rod End Bellow They are strong due to hardening processes they undergo, hence have high ability of protecting exposed rod surfaces. The protection prevents destruction from contaminants such as cement. Disadvantages of Rod End Bellow Their closed length creates a disadvantage such that they affect required and appropriate building length of the cylinder. Manufacturers must therefore face extra cost in seeking longer rod extensions to solve the problem of closed length. Physical Properties of Rod End Below ISO No. Rod protection Have rod end bellows ISO 60 0/ Abrasive Exist as a semi liquid iii. Chromium Plated Bars Chromium plated pistons are among the rods used to manufacture hydraulic cylinder piston rods. The pistons come in various materials, for instance, CK – 45, 42Crmo4, Nikrom, 20Mnv6 and hardened steel. The outer piston receives a treatment of up to f7 tolerance with chromium coating that has a thickness of about 10-20 my depending on the diameter on the piston rod. Advantages of Chromium Plated Bars The chromium-plated rod has an advantage because it has induction hardening that makes it easy to construct especially in difficult working conditions. Chromium plated rods materials are also appropriate in situations that extreme weather conditions because they have Nikrom or INOX as alternatives. Nikrom and INOX are high quality materials that have great capabilities of surviving even extreme weather conditions such as strong heat and heavy rainfall. The chromium-plated bars also possess the characteristic of easy size-ability. This means cutting them into desired dimensions is easier during construction as well as treating as per the requirements of the installing firm or individual. Disadvantages of Chromium Plated Bars However, plating the bars with chromium gives a challenge to users especially in terms of time and cost. Chromium takes about 500 minutes to treat a considerably shorter length of the bars, making it time consuming. Secondly, chromium is an expensive element making it difficult to acquire large quantities that would be sufficient in treating the bars for manufacturing hydraulic cylinder bars. Physical properties of chromium plated bars Chromium plated bars Have hardened induction case ISO No Have chromium plating ISO 9001: 2008 Can be easily cut into sizes Resistant to breakages Most Suitable Material for Manufacturing Piston Rod of Hydraulic Cylinder Chromium plate bar is the best material for the manufacture of piston rod for hydraulic cylinder. Chromium plate bar has great capabilities that guarantee not only durability but also efficiency. Hardened steel in the plate makes it highly durable as Nikron and INOX provides it with ability to survive adverse weather conditions. Its induction hardening enables easy and smooth construction where working conditions are not very favorable. Chromium plated bars also make manufacture of piston rods easier because they are easy to cut into smaller sections depending on the manufacturer’s desires. The kind of treatment given to such bars makes them highly resistant to destruction, as they remain highly efficient in terms of performance. In addition, the fact that chromium plated bars comes in different types of materials make their application more flexible. For instance, where Nikrom is not applicable, 42Crmo4 may come in handy to save the situation. Materials for Manufacturing Tube of Hydraulic Cylinders i. Seamless Tubes Seamless steel pipes are some of the materials used to manufacture hydraulic cylinder tubes. The seamless tubes have advantages that include cured tensile strength that can go up to above 52 kg/cm2. Achievement of tensile strength comes through the process of gradual heating as well as cold forcing. Advantages of Seamless Tubes Seamless pipes can regulate inner diameter to as low as H8-H9 level. It also helps in extending the life cycle of hydraulic cylinders by protecting the seal from tearing and wearing because of its surface roughness. In addition, the tubes have skiving applications as well roller burnishing that ensures durable quality for the hydraulic cylinder tubes. Further, seamless tubes achieve proper efficiency through geometries that are exceptionally precise with high strength making it more durable. Disadvantages of seamless tubes The only disadvantages seamless tubes pose to the construction of hydraulic cylinders is that they are relatively expensive. Seamless tubes cost approximately £813 per unit. The seamless tubes also have slightly thicker walls that are contrary to the desired thin wall thickness that guarantees lightweight to the hydraulic cylinder tube. Physical Properties of seamless tube Seamless tube Cured tensile strength ISO No Have skiving applications ISO 10893-10 Have a roller burnishing effect Have thicker walls Strong ii. Floating Plug Floating plug remains the best choice to utilize as a material for controlling the tube internal diameter (DE Garmo et al., 2012, p. 426). The plug design takes the specifications of material such as reduction and possibly friction. The flowing tube pulls it far forward in situations when friction is too great. Advantages of floating plug Floating tubes help in shaping and sizing the internal diameter within the hydraulic cylinder tube. It is also important in situations where internal diameter required is of long length because it is efficient at achieving a stable position. Disadvantages of floating tubes It is not efficient in resisting and reducing high friction and tension. Physical properties of floating tubes Floating flag ISO No. Have definite shape Have definite size ISO 6020-2 iii. The Drawing Bar The drawing bar is useful in making products that have cross-sections. It emerges with excellent surface finish and a precise dimension especially when manufacturer uses cold drawing. Advantages of the drawing bar It is also important because of inexpensiveness and easily used to replace stronger bars that require additional heat. Bars that have cold-drawn shapes are sectioned economically to produce the individual cross section products. Disadvantages of drawing bar It comes with the limitation of requiring high accuracy to produce desired cross-section sizes. Physical Properties of Drawing Bar Drawing bar Precise finish ISO No. Have cold drawn shapes ISO 6020 & ISO 6022 Most Suitable Material for Manufacturing Tube of Hydraulic Cylinder Among the three application materials, seamless tube remains as the best material to construct the tube of a hydraulic cylinder. The reason that makes it most appropriate is because it can regulate the expansion of inner diameters of the tube in whichever environment and situation. Its tensile strength is also one of the best because it is capable of changing shapes to suit whichever situation during and after construction. Ethical Issues Most of the materials used to construct hydraulic tubes are more environmentally friendly. Particularly, seamless tube made of green pipe does not pose any environmental challenges to the living organisms. In addition, seamless tubes have manufacturer’s labels that give direction on how to utilize it in sustainable manner to avoid posing environmental hazards. Cost of Chromium Plated Pistons According to cylinder sheet of prices, best cylinders that guarantee top value to users give the prices listed below with desirable discounts attached to it. The chromium piston materials listed here have an added advantage of piston coatings. Repairing them is easier and environmentally friendly. Users too do not face challenges due to exposure to such materials. Price Listing For Chromium Plated Piston Aluminium Cylinder NiCom Electro Plating (Per Bore) £199.00 Bore, Stip, Hone to Standard Size, NiCom £230.00 Weld, Strip, Bore, Hone to Standard Size, NiCom £262.00 Cylinder Exchange (Applicable for core deposit) £249.00 NiCom Plate on Steel Bore or Cast Iron £282.00 Big Bore Cylinder Upgrade £262.00 Hone Cast Iron and Bore £75.00 Cut Cylinder Base or Deck Top with per each service prices £50.00 Line two Piston Skirt Coating £35.00 Custom two Stroke Porting (Trail Porting or Race) £125.00 Expedited three-five days Express Rush Service First Cylinder $7 with every added Cylinder $25 per Order £75.00 Light Diamond Plateau Hone £45.00 Head Modification--needed for upgrading a big bore on most applications £65.00 Modification of Exhaust Valve needed for cases involving upgrading of big bore cylinders with equipped valves £50.00 Removal of Power Valve £35.00 Service related to Power Valve: Clean, Remove and Install Power Valve System £70.00 Source: US Chrome (2013) All the above metals are all environmentally friendly because they have coatings of non-reactive substances such as carbon, steel and chromium. Users also enjoy a wide range of safety measures during construction of a hydraulic cylinder facility. Bibliography DE Garmo, E. P., Black, J. T., & Kohser, R. A. (2012). DeGarmos Materials and processes in manufacturing. Hoboken, NJ, Wiley. US Chrome, (2013). Cylinder Plating, Piston Coatings, Diamond Honing and Big Bore Pricing Info. New York. Retrieved on January 14 from http://www.usnicom.com/plating/pricing. Read More