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LED Screens
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Enhance the Big Event Experience with Big LED Screens

by norwegianprototypes
written by norwegianprototypes

Gone are the days when the big screens were only for watching movies. Today you go to any event the big LED screens are a must, and why not they are an amazing way to advertise both indoors as well as outdoors.  Big LED Screen grabs the attention of this new generation in every event. Be it a race day experience, a cricket match in the stadium, or commercial exhibitions and more. Big LED screens enhance the experience of their crowd, think of a cricket ground without the LED screens, they have become a necessity than a choice. Whether you are planning a film premiere or want to do a sponsored promotion display in a commercial exhibition, LED big screen is a great way to get noticed.

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You might think that setting up these LED screens are complicated and may have tons of questions in your head.  Always buy them from an authentic place like Bibi Led, as you will get all the support you need. Pre-sales support of engineers, who can answer all your questions, provide solutions as well as an end to end technical training and customized post sale support.

If you think you don’t really need a Big LED screen for your big event, then it’s time to think again. Read through the article to get a clarity on the impact of LED screens in today’s generation when everyone needs something extra to remember even the Gala events.

Why LED Screens?

The foremost reason is LED screens has the highest quality of pictures any other screen can produce. LED is a small panel of three different lights that is red, green and blue, which creates a pixel of an image. One doesn’t have to bother about the size of the screen, as because a huge number of pixels can be combined together to form a never-ending screen without compromising on the quality of the pictures.

Benefits of LED screens

Something that can bring spark to your big event is LED screens, mentioned below are some of the benefits of having a big LED screen in your event.

  1. LED screens can be used both for outdoor as well as indoor events. Though the pixel pitch would differ, you will have to specify your need and purpose while buying one from Bibi Led.
  2. LED screens have high definition image transmission technology that gives excellent picture clarity even during the daytime without any impact of the daylight. The screens for outdoor events are waterproof so you don’t have to bother about any type of weather condition.
  3. LED Screens are flexible and they can be fixed even in conventionally tight places. Whether you are playing a video, an audio or a sponsored promotion, you can be assured that the audience has definitely seen what you wanted them to see because of their brightness.
  4. Usually it is difficult to communicate with your audience in a big event because of huge crowd, sound etc. And announcing instructions or certain guidelines again and again can spoil the event, displaying your message or content on an LED screen is a great way to convey message to the larger audience.

    LED Screens

    LED Screens

The budget might be a concern at the first thought but one cannot underestimate the power of visual impact in today’s time. Audience buys stuff from brands they can recall and LED big screens are a great way to get into a customer’s head. With trusted brands like Bibi LED that meets US standards and are compliant, get all your LED Screen solutions under one roof. Leave your mark on your audience with LED screens and reap the long-term benefits.

 

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Uncategorized

Ebike Battery: Which One Should You Choose?

by norwegianprototypes
written by norwegianprototypes

An electronic bicycle is a great technological revolution of recent years. The battery-driven version of a conventional cycle is making the world a better place to live.

E-bike runs on a battery which gives power to the electric motor attached to the rear wheel. The electric motor gives you the extra power you need when you are tired pedaling on your bicycle.

Considering the several advantages of e-bikes like cost-cutting, environment-friendly etc, it is a preferable choice for daily commuting. All you need to is charge the battery when low and you are good to go.

However, E-bike’s battery comes in different variations. If you search in the market then you would find many types of electric batteries that you can install in an e-bike.

 

Types of E-bike Batteries

Sealed lead to lithium-ion, 36v to 48v ebike battery there are many kinds of batteries available for e-Bikes. Every kind of battery can fulfill your purpose, however, performance and durability is different with every battery.

  1. Sealed lead-acid Batteries:

Sealed lead-acid is one of the oldest kinds of battery, The greatest advantage of these batteries is the cheaper cost. Also, you can recycle them with no trouble.

If you are a DIY person then this kind of battery would help you to make your own e-bike easily.

Downside of a sealed lead-acid battery is that it is heavier in weight and store less electric power. In difficult weather conditions lead acid battery might not be the best choice.

  1. Lithium-ion Batteries:

Since its arrival Lithium-ion battery has proved to be a game changer of the battery world. Many devices including mobile phones, tablets, power banks etc use lithium-ion batteries.

Lithium-ion battery is a better solution as it provides more stable power to the e-bike. The weight of the battery is less compared to lead-acid and capacity is higher.

Also, in different weather conditions lithium-ion battery outperform its competitors by a big margin.

  1. Lithium Phosphate Batteries

Lithium phosphate is the subtype of Lithium-ion battery. The base technique of making lithium phosphate is same as lithium-ion however, lithium phosphate can hold up more power.

If you want a battery that provides a great boost of power then lithium phosphate battery is a nice option.

  1. Lithium Cobalt Batteries

Lithium cobalt battery is a popular battery kind, a majority of e-bike brands are using this type of battery in their e-bikes. The upside of this battery is the higher power density and small size.

With Lithium cobalt battery you can expect more battery life. Also, they handle high and low temperatures better than other types of batteries.

 

Which one is best?

All batteries have some advantages and disadvantages. So, it becomes a matter of choice. Some people want durability, some want high acceleration, some want to carry less battery weight. According to your need, you can choose the right battery for your e-bike.

However, If I talk about a complete winner that performs well in any situation it is Lithium cobalt battery.

 

Final words

Choosing an energy efficient battery is very important for your e-bike, after all, you want a hassle-free daily commuting, right! With help of this article, you can decide which battery you want to buy for your electronic bike.

If you want to share your viewpoints or if you have a question to ask, please write in the comments box below.

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Centrifugal pumps
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What is Centrifugal Pump and its Working Principles?

by norwegianprototypes
written by norwegianprototypes

Arc ValveGenerally, pumps are the most important devices in any industry. But what is a pump? This is a device that transfers fluid from one point to the other. However, there are two types of pumps.

  • Centrifugal pumps
  • Positive displacement pumps

There are many different sub categories of pumps. But the two above are the main types of pumps. However, in this article I am going to focus more on the working principle of centrifugal pumps. Centrifugal pumps convey fluid by the conversion of rotational kinetic energy to the hydrodynamic energy fluid flow.

Background Information of Centrifugal Pump

Centrifugal pump

Centrifugal pump

The invention of centrifugal pumps was done by Denis Papin a Physicist in 1689. The centrifugal pump is one of the most used pump in the world currently due to the following reasons.

  • Cheap to construct
  • Strong
  • Delivers fluids faster than other pumps
  • Simple

But centrifugal pumps need to have protection when a fluid is flowing. An Arc Valve is best protection for centrifugal pumps. The arc valve protects the centrifugal pump from cavitation damage and overheating. Unlike other pumps for centrifugal pumps when the radius of the impeller is high the faster the transportation of fluids.

Types of Centrifugal Pumps

Like said before there are different types of centrifugal pumps. They include:

  • Vertical centrifugal pump
  • Froth pump
  • Multistage centrifugal pumps

Vertical Centrifugal Pumps

Also known as cantilever pumps this is a type of centrifugal pumps. The vertical pump is used in parts washer. A device used to remove contaminants like

  • Carbon
  • Ink paint
  • Oil
  • Grease
  • Metal chips

And other types from a workpiece. This pump has a unique shaft and bearing support that allows the volute to hang in the sump while the bearing is outside the sump.

Froth Pumps

This pump is mostly used in the mining industries. This pump is used to separate minerals from sand and clays. Froth pump has air that tends to block the pump. This type o centrifugal pump is constructed in a way that it cannot block when froth is conveyed through it.

Multistage Centrifugal Pumps

Centrifugal pump

Centrifugal pump

This type of centrifugal pumps contains two or more impellers. In most cases the impellers are attached on the same shaft for efficiency. This pump increases the pressure which the fluid is discharged out from the pump. In addition, the impellers are connected in parallel. Multistage centrifugal pumps are mostly used in the boiler section of sugar industry. Specifically, as the boiler feedwater pump.

Uses of Centrifugal Pumps

There are many uses of this item. They include:

  • They are used to transport water over a wide region due to its high pressure
  • Used in fire sprinkler systems
  • Used to circulate hot water
  • Used for drainage
  • Used for air conditioning systems

Conclusion

There are many applications of centrifugal pumps. However, I cannot cover all of them. But you need to know it has vast application. They are used in many industries. Apart from its applications they also have different classifications. For example, there are centrifugal pumps classified due to impeller design. So, when you want a centrifugal pump ensure you have in depth knowledge about them.

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Factors to Consider When Evaluating Contract Manufacturing Bids

by norwegianprototypes
written by norwegianprototypes

Do you intend to engage a contract manufacturer in your business? Which strategies will you employ to get value for your investment?

Most people make the mistake of selecting the contract manufacturing firm with the lowest bids. While this may help in cutting costs, it’s not the best option. Here’s why.

In most cases, the lowest bid doesn’t have all the services you need. It’s also very common for these firms to exclude important manufacturing process- quality assurance and control- from their bids. In the end, it’ll cost you more money to fix the problem.

Evaluating these bids is a task that you shouldn’t take lightly. There are different factors to consider. They’ll include a review on customer service, contingency plan, and supply chain and quality assurance.

You may need to ask yourself these questions when evaluating a bid.

Contract Manufacturing Bid

Contract Manufacturing Bid

  • Does the Bidder Have the Capacity to Deliver on Your Contract?

Evaluating a bid is like making a purchase and investment decision. You’ll need to evaluate everything. Don’t limit yourself to price and experience only. Assess their IP safeguards, competence, and financial stability among others.

When communicating with the bidders, be sure to ask as many questions as possible. Ensure they are all related to the services you seek. Evaluate the responses they give to determine whether they have the skills you need.

  • After Signing the Contract, Will they Offer any Customer Service?

Customer service is key in a contract manufacturing exercise. It’s even important where the companies are in different geographical areas.

You’ll need to maintain a constant communication channel at all times. You may need to make a requested change, address a manufacturing problem or inquire about the delivery process.

Your communication process with the contractor needs to be simple and smooth. Otherwise, your contract will always lead to frustrations and headache.

  • How Does the Manufacture Manage Quality?

The quality of a manufacturing exercise is a process. It begins with inspecting your raw materials and ends at packaging the products effectively for shipment. How will the manufacturer manage the entire process?

A competent contractor will maintain a decent record for every manufacturing stage. Its staff will be able to answer any question you may have concerning the process. They’ll also keep updated on each issue that arises in the manufacturing process.

  • Does the Manufacturer Have a Contingency Plan?

In every exercise, there is always a probability that things will go wrong. So, what will the manufacturer do if things go wrong? There’s nothing like expecting the unexpected. But still, the manufacturer can predict some challenges and find advance solutions.

As such, ask their contingency when any of these situations arise:

  • What if there is a delay in the supply of raw materials?
  • What if an emergency situation that makes it impossible to ship products?
  • What if there is a problem with the power supply? A labour problem?
  • What if a company experiences a major line failure?

A good company will foresee these problems. As such, it’ll have the best solutions in place to curb them.

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Top 10 ERP to be watch-out for in the Manufacturing Industry

by norwegianprototypes
written by norwegianprototypes

 

In a typical manufacturing establishment irrespective of its area of focus, there are bound to be some areas and departments lagging. While some of them need to be scrapped, what so many more need is simply better management. It could be time for you to couple physical management with software management and as an organization, what better way to do this than with an ERP?

er3

ERP, Enterprise Resource Planning in full, is a software that comprises various applications and systems used by organizations and businesses during the carrying out of their daily operations and activities. These activities and operations include manufacturing, sales and marketing, procurement, project management, accounting, etc. ERP helps connect these processes and operations in an organization to make said organization productive, work smoothly, and run efficiently, with the end game of seeing the organization grow and make profit.

Without further ado, below are the top ten best ERP software systems for establishments in the manufacturing sector:

  1. Brightpearl

 

This product which comes first on this list is a multi-channel system that has the capability of handling a large scale of business activities and operations, including accounting, reporting, inventory, customer data and orders. It also has flexible plans when it comes to its pricing to accommodate the varying budget of organizations.

What makes Brightpearl standout?

  • The Brightpearl ERP software is built for retail
  • The system is pretty affordable
  • Brightpearl software system also comes with a single information hub
  • Automated accounting
  • It has a comprehensive omni-channel platform
  • Brightpearl has a centralized inventory management

     2. Intacct

 

This system is a cloud-based software used for financial management. It was created for medium-sized establishments that seek solutions to malfunctions in their daily activities and operations. Intact is a versatile software specifically designed to increase establishments’ productivity, boost efficiency and help the business grow significantly in the long run.

What makes Intacct stand out?

  • Its interface is simple and clean.
  • Intact comes with a wide range of core accounting capabilities
  • Safe and fast payment processing
  • It has a scalable system
  • It offers solution for finance professionals
  • Built-in and customizable reports

 

   3. Infor VISUAL

This system was designed with manufacturing establishments who constantly seek a permanent solution to their whole operational lifecycle. Infor VISUAL offers overall functionality that covers all the operations carried out by the organization. It is presently being used by lots of manufacturing organizations especially those involved in aerospace, automotive, electronics, defence, etc.

What makes Infor VISUAL stand out?

  • On-time delivery
  • Complete visibility
  • Accurate operation
  • Full scalability
  • Efficient quality controls

 

  4. Sage 100 ERP

This ERP system is a software that was created for the purpose of delivering complete operation and financial functionality. The Sage 100 ERP comes with inventory and manufacturing features and comprises various modules aimed at covering several day-to-day operations.

What makes the SAGE 100 ERP stand out?

  • Its platform is highly-modularized and user-friendly
  • Stable and customizable
  • Built-in templates
  • Back-ups and security
  • The SAGE 100 ERP comes with its own customised sage data cloud

 5. SAP Business One

er2

This system is a management tool made to reorganize the flow and storing of information through all the various scales of business.

What makes the SAP Business One stand out?

  • Automated financials.
  • It comes with a single data hub
  • Streamlined procurement
  • Efficient CRM.  
  • Integrated platform.

 

 

 6. NetSuite ERP

The NetSuite ERP is an integrated management software built with applications to deal with ecommerce, CRM, financials, and ERP. According to the last statistics taken, this software is presently being used by over 40,000 establishments.

What makes the NetSuite ERP stand out?

  • It is produced by the 2nd biggest software producer in the world – Oracle
  • Fast track quote-to-quote process.
  • It offers organizations complete visibility of their supply chain.
  • Accurate revenue recognition.
  • Optimized recurring revenue streams.
  • Streamlined fulfilment flow

 

 

 7. PeopleSoft

Another Oracle product on the list, PeopleSoft was created to help organizations boost their productivity via its collection HR functions.

What makes PeopleSoft stand out?

  • It is an Oracle product
  • Labour rules and monitoring.
  • Global HR management.
  • Connected applications.
  • Workforce management.

 

 

8. ECount ERP

 

erp1

This system is a software that allows organizations manage their day-to-day activities and operations such as sales, purchasing, production, accounting, and human resources all through a cloud-based system.

What makes the ECount ERP standout?

  • Unlimited users
  • Sales management
  • Accounting platform
  • The software is budget-friendly
  • Extensive features list

 9. Odoo

 

This ERP software comes with various functions aimed at increasing establishment’s productivity. It is different from the basic management software systems in different ways such as coming with a free basic plan for a single application that can accommodate up to 50 users, and the fact that it covers and enriches project management and essential sales with ecommerce, POS, and MRP functions, all in a single platform.

 

What makes Odoo stand out?

  • Free basic plan and a lifetime package at zero cost
  • Highly modular
  • Universal solution

 

 

10. FinancialForce ERP

Last but not least, the FinancialForce ERP is a software built for establishments that wish to make the transition or switch from a CRM platform to an ERP platform. The software helps arrange and organise your sales, finance, HR, etc. apps to give you (the establishment) the capacity to act from anywhere and clear visibility.

What makes the FinancialForce ERP stand out?

  • The FinancialForce ERP connects everyone.
  • Financial prowess.
  • It helps grow and update your ERP.
  • It combines CRM and ERP platforms
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Manufacturing Process
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Manufacturing Process and Its Classification – A Complete Guide

by norwegianprototypes
written by norwegianprototypes

Manufacturing Process is one of the main parts of the production process. It is that process which involves the changes of sizes/dimensions or shape of the part. Transportation or material storage is not a part of the manufacturing process. This article is dedicated to explaining different types of manufacturing processes.

Manufacturing Process Classification

Different materials are needed for manufacturing. So before starting the manufacturing process the properties of the engineering materials should be known. Available engineering raw materials needed for manufacturing, equipment, tools, and machines all are of great significance.

These materials, equipment, tools, machines are mainly made of metals which are collected from ores. The metals are extracted from the ores and then molten metal goes through some foundry processes. Pre-foundry processes involve the purification of the metal. These pure molten metals are poured into the moulds and thus we got ingots. These ingots are processed in some other mills to get the desired shape. Thus we get billets, blooms, slabs, sheets and rods or tubes. These shapes further go through some other processes and usable shapes are obtained. Usable shapes are done in different machining and manufacturing shops. We will discuss the six major groups used to convert ingots into usable metals. So let’s start-

complete manufacturing techniques

First One – Primary Shaping Process

Primary shaping process is used to give the amorphous material a well-defined shape. Some of the primary shaping processes produce final products and other needs additional machining works. Primary shaping process involves casting process, plastic forming technology, powder metallurgy, bending of the metals, forging and gas cutting and many more. For example, in casting technology, the molten metal is needed to be poured on the moulds and it needs to cool down. Afterwards, the cooled metal object may need some extra machining through grinding or lathe machine or some milling operation.  Please Read: Different Casting Process Explained. 

 Second- Machining process

As mentioned earlier primary process may not give the complete finished goods. Machining is one of the processes of making the primary shapes into finished goods. The components or parts are subjected to machine shops for finishing. It is used to give desired shape and size to the cylindrical and flat objects. The process to remove unwanted materials from the jobs using cutting tools is known as machining. The purpose is to give perfect dimension and desired shape. Machines used for these operations include lathe, milling, drilling, shaper, planner etc. The materials subjected to machining operations include the shapes of a bar, rod, tubes and flat surfaces. For greater dimensional accuracy and surface finish the machining processes are important. They also provide the good surface finish. At the time of machining different multi-point cutting tools, jigs and fixtures and measuring devices are used. Machining produces a lot of waste metals in the form of chips. These days CNC machining is used for better accuracy and quick machining. Turning, knurling, parting, facing, boring, reaming, slotting, punching, threading, milling, gear cutting are some of the metal removing processes. For a better idea about machining tools follow The classification of machining tools. 

Third – Metal Forming process

Metal forming is another manufacturing technique used to give the metal desired shape through the application of pressure/stress, forces like compression or tension or shear or the combination of both. By applying these forces permanent deformation of the metal is achieved. These processes are also known as mechanical working processes. These mechanical working processes are classified into two categories, one – hot working processes and two-cold working processes. Metal forming process does not incorporate metal removing. The metal is deformed and sometimes displaced by the application of forces. Metal forming always include plastic deformation. In this technique, directly usable articles can be made. Wires, rods, cold drinks bottles, tubes are made by the metal forming process.  The hot working process includes forging, hot spinning, rolling, extrusion, hot drawing etc. Cold Working Process include cold forging, cold rolling, sheet metal working, punching, piercing, squeezing, notching etc.

Fourth –Joining Processes

Joining is a process we are using in our everyday life frequently. Different sub-assemblies are joined together to get a completely assembled product. In fabrication process joining is used frequently. In manufacturing or fabrication, two or more metal parts are put together and joined by means of fusion, riveting, screwing, applying pressure and rubbing. These joining processes are needed to make air-tight joints and semi-permanent and permanent fasteners. These joining techniques are very important in making bigger assemblies. For example, an aeroplane is assembled by putting together more than a thousand subassemblies. The joining process includes different types of welding, soldering and brazing, riveting and screwing, pressing, nut and bolt joints etc. Please Read:

Fifth- Surface Finishing

Surface finishing is a process which is applied to get the desired levelling of the surface and also to obtain the desired smoothness. Very negligible amount of the materials is removed from the surface by this process and does not involve any effective change in the dimensions. It is not an effective metal removing process and should not be confused with the machining process. Putting some kind of coating over the metal is also a surface finishing process. Various surface finishing processes include honing, lapping, super finishing, sanding, deburring, electroplating, buffing, painting, anodizing, galvanizing etc. Sherardizing, Parkerizing, plastic coating or metal spraying is also known as one kind of surface-finishing process. Surface finishing provides excellent finishing of the metal surface and at the same time gives good protection from the environmental contaminants.

Sixth- Processes that involve the changes in the material properties

Different properties of the same metal are desired for different applications. So metal property is needed to be changed in those cases. Material property change may include improved hardness, greater ductility, durability etc. For some particular uses or operations, suitable properties are needed to be incorporated. Some operations need softer material, some need harder. The properties of the materials change when the total grain size of the materials are regrouped or reorganized. Different grain conditions provide different properties. The grain sizes are changed by the application of different heat treatments. By heat treatments, the internal structure of the material is changed. And they achieve different improved properties. Common heat treatment methods include –annealing, hardening, case hardening, normalizing, grain refining, tempering and age hardening etc.

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prototype model
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The Complete Methodology for Prototypes

by norwegianprototypes
written by norwegianprototypes

If you are going for a product manufacturing in a large scale it is always necessary to build a prototype. The prototype is a functional product which is similar to the final or finished product but it may not be fault proof. So making a prototype and modifying it till it is flawless will help the final product to become completely defect free. From a prototype we can learn and also tests can be performed. For incremental development the prototype making is significant. The quality of the product and the business expectation have to be kept in mind while designing the proto.

Please Read more manufacturing articles here:

Manufacturing product through the prototyping

Some basic things should be kept in mind while designing the product prototype.

  • The idea should be simple.
  • The perfection cannot be achieved by one trial.
  • You have to have a clear idea about the options and limitations you have in your manufacturing plant.

Achieving the product from your innovative idea

For achieving your targeted product you have to maintain these five steps

  • Documentation – It will help you keep the records and you can derive something from the previous working experiences. It will be also good for ISO certification if you are looking for one.
  • Continuous Research- These days research is very easy. Thousands of models are there for almost every product on the internet. Also, journals and publications are there. So take ideas and research it for making the product unique.
  • Manufacturing- After those two steps start building your prototype. Then test it. Look for errors. After doing trials make it perfect.
  • Patenting- Patent the product. It is your innovation so patenting is necessary.
  • Marketing- After the patent start for the marketing. Without marketing, you will not be in a position to sell it.

Steps involved in making the prototype realistic and obvious for manufacturing

Complete Prototype Methodology

Defining your main goal:

A good team is needed to define the goals with whom you can discuss. The brainstorming is also needed. So asked your team to work on the prototype and figure out the problems that can occur and find the ways to resolve it.

A limited amount of options:

Don’t think too further for developing the proto. If you have defined the goal then collect the best ideas and methods. Stick to the limited features. It will help to refine it further along the way.

Designing from scratch

Start designing your prototype on the paper. It is an old method but it always provides a better understanding of the concept. A preliminary design is needed to be done in the paper. This design should have as many details as possible.

Sharing and collecting feedback

Discuss with the people involved in the design work about the concept you developed on the paper. It can be shared with the stakeholders for making it more realistic. The creative team, clients, managers of the productions should be included in providing the feedback. A thorough evaluation of the prototype will give a clear idea of the feasibility, strength, and weakness of the prototype.

Editing

Edit and modify your design after collecting the feedback from the people. The design can be scaled down for the necessity of the testing.

Perform the CAD

After the finalization of the design put it in the CAD and engage your draftsmen to give it the professional look.

Ask for approval

You are creating the prototype for manufacturing. So your complete design is needed to be approved by the client. Get the approval of the client. If the prototype gives an actual feel to the customer it will be approved easily.

Continuous Documentation

Documentation should be going on continuously for the future reference.

Advantages of the prototype Model

  • Prototype verification actively involves the clients or the customer in the process. It improves the product quality.
  • The working model of the actual product is visible in this methodology. So the clients are getting a better idea of the product.
  • Almost error free designing can be ensured as the errors are identified and rectified at an early
  • Before entering the final manufacturing process client feedback is available. It helps to understand the client demands and leads to a better
  • Problems in the functionality are identified at an early stage.
  • Confusing features and difficult functions are understood by the client as well as the designer while following the methodology of the prototype.
  • With the help of the prototype users with a lesser idea of the product can get a decent idea.
  • Prototype building is advantageous for both users and manufacturer. Sometimes the client is not confident about the capability of the manufacturer. After building a model prototype the customer gets an idea and the manufacturer gets a chance to prove himself.
  • Prototyping removes the risk of failure. Potential risks are identified and removed earlier.

Disadvantages of the Prototyping

  • In this method, the processes or techniques are applied and then repaired and finally, you need to build another prototype as the final one.
  • The methodology can be very complex. The continuous modification and concept developing can lead to a more complex system which may expand beyond the original idea.
  • The incomplete idea or the insufficient problems analysis can lead to an incomplete Which may not be used in the final manufacturing.

 

The perfect places to use prototype models

  • The prototype should be used in the places where the end users are directly involved and have a lot of interaction with the system.
  • These days the online works and web developing needs the direct involvement of the customers. In these cases, the prototyping is very good. It takes time but prototyping is best suited for the online works or UI development etc.
  • Any kind of new vehicle design always needs a final prototype design. It will be tested with the prototype and finally, the product will be manufactured.
  • Most of the cases all the mechanical products or parts are needed to be built as a prototype
  • The prototype is needed at those places where refining and testing the functionality of the design is a must.
  • To reach the desired performance level prototyping is essential.

To get a complete concept of the prototypes, follow this link:

 

 

 

 

 

 

 

 

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welding with mig gun
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MIG Welding Principles and Its Application in Manufacturing

by norwegianprototypes
written by norwegianprototypes

MIG or Metal Inert Gas welding is a special type of welding used for non-ferrous metals. It is also known as Gas Metal Arc Welding or GMAW. It is similar to the other arc welding processes where a consumable electrode is used to melt and join the metals. The arc is formed in the gap between the metal and the electrode. But it is different from the other welding processes as it uses a shielding gas while performing the welding. This is done to keep the welded joint free from the atmospheric contaminants. It first started in the 19th century and since then it has gone through a number of development processes.

Basic Principles of Metal Inert Gas (MIG) welding

The equipment required to perform the GMAW include

  • Welding electrode which should be fed continuously with the feed unit.
  • Welding Gun
  • Welding Power Supply
  • Inert gas (Shielding gas) supply

Please read:

Principles and techniques to perform MIG welding

  • The arc will be generated by the common arc welding process.
  • The electrode in the form of a wire will be fed continuously with the feed unit.
  • Along with the electrode feeding, the inert gas will be flown continuously from the welding gun.
  • Feed mechanism can be semi-automatic or automatic.
  • With constant voltage supply, DC or AC, both supplies can be used.
  • At the time of welding, the wire is fed by pressing the trigger or the control switch. This switch also triggers the inert gas flow and starts the power supply. Thus an electric arc is struck.
  • The welding tip generally manufactured by the chemically treated or bare copper is attached with the welding electrode. The copper tip is connected to the power source and supplies power to the electrodes.
  • The gas nozzle will supply the shielding gas uniformly. It will cover the welding area. And the whole process will be free from oxidation. It should be checked that the flow of the gas is consistent or not. Insufficient flow of the gas will not protect the welding area properly.
  • For high heat operations, a cooling water jet is very significant. Some machines have the provision of supplying water in the welding gun itself.
  • Before welding, a welder needs to check his welding electrode holder. Semi-automatic water-cooled, fully automatic water-cooled and manual air-cooled electrode holders are available.

MIG welding basic Principles

Advantages of MIG welding

  • Superb quality welded is produced within very less time.
  • Flux is not used in MIG process. So slag entrapment is there. High-quality weld is produced without any contamination.
  • The arc shields provide protection to the arc. So very less power is lost in the environment from the alloy. The weld spatter produced is also very less.
  • Different types of materials can be welded in MIG. It is a very versatile form of welding.
  • Semi and fully automatic processes are there. So it is very effective and easier to use.
  • The weld pool is easily visible. So it is very easy for the welder to perform the welding.
  • Very less post-welding cleaning required whether in normal arc welding it requires a lot of cleaning and treatment.
  • MIG welding provides higher rates of production. In MIG there is no need to change the electrode. There is no slug removing process needed. So welders can enjoy a faster and cleaner welding process. The productivity increases a great deal.
  • Actually, MIG welding is very easy to perform. Even a technician with basic welding idea can perform MIG. But TIG welding is much tougher than the MIG.
  • While performing the MIG welding, both or at least one hand remains free as the electrode is continuously fed by the feeding mechanism. So a faster welding with great quality is observed.
  • The deposition rate is higher in MIG welding.
  • The process is ultra-low hydrogen process.

 

Disadvantages of MIG welding

  • The MIG use is limited to horizontal welding technique. It cannot be used in vertical or overhead positions.
  • The equipment setup is complex. Also, the equipment is not portable. So complex and costly setup is involved in MIG process.
  • The setup of the machines can be highly expensive at the beginning.
  • Welding in outdoor conditions is very tough. In outdoor conditions shielding gas cannot be used properly as the outdoor conditions are not stable. The process can be used in draught free conditions.
  • Additional electrical components are there so extra maintenance cost may be needed.
  • Skilled manpower is needed to set up the welding plant.
  • Some radiation effects are there. And it is severe than the normal welding conditions.
  • Not efficient enough for the products where the high duty cycle is needed.
  • Surface preparation is a great issue for the MIG welding. For doing MIG welding the surface should be free from dust and dirt. So before performing the welding some treating of the metal surface is needed. It there is rust then it should be removed too.
  • Thicker metal welding is tougher in MIG. If the material is too thick then MIG does not work well.
  • MIG sometimes provides incomplete fusion welding defect.

Applications of Gas Metal Arc Welding Technique

  • The automobile industry has a huge use of MIG welding.
  • Heavy constructions like bridges and building materials are welded using this process.
  • Pipe welding can be done efficiently with MIG. There are different types of welding apparatus to weld the pipelines using MIG.
  • MIG welding, if incorporated with robotics can be used in amazing automotive repairs. Heavy, medium to light all types of automotive vehicles can be repaired with ease. The welding is strong even if the thickness is limited to 0.5 mm. Before MIG, it was very difficult to weld automotive repairing parts.
  • Worn-out railways tracks are easily repaired with MIG.
  • Rebuilding is an important property of MIG that is used frequently. It is a form of repairing that can be used easily.

MIG welding is great for welding complex shapes and sizes. It is very versatile welding with great potential. As the process is easier to use it does not require any skilled technician to operate the machine.

For more welding related articles please visit:

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TIG welding basics
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TIG welding Working Principles and Applications

by norwegianprototypes
written by norwegianprototypes

TIG welding stands for Tungsten Inert Gas Welding. It is one the metal inert gas welding used frequently in the manufacturing industry. It is also known as Gas Tungsten Arc welding(GTAW). It is used in those cases where high purity is needed to be maintained in the welded joints. For example, you cannot imagine nuclear power-plants, aviation companies, food and beverage companies and pharmaceuticals without the application of TIG welding. Most of the times it is used for welding non-ferrous metals. Like any other inert gas welding, it uses an inert gas for shielding. Most of the times, Argon or Helium is used for the inert gas shielding.

Please Read Different Types of Casting Process and their advantages. 

For more info about TIG, you can go through TIG advantages and Disadvantages 

TIG welding Working Principles

There are some basic differences between Metal Inert Gas (MIG) welding and the TIG. In the MIG the metal is continuously fed as a filler metal while doing the welding. But in TIG the base metal is melted and the filler metal is hand fed at the same time. The Tungsten stick is not consumed and works as an electrode.  So the basic difference between TIG and MIG is the non-consumable electrode used in TIG. While the welding process is going on the total welding area is shielded by the inert gas helium or argon. The inert gas is used to avoid the contamination of the welds from the environment.

TIG is not an easy task. It is the most complex form of welding. Let’s discuss the techniques-

Techniques for Performing TIG welding

  • The angle of the welding torch should be 15-20 degrees apart from the direction of the welding. This is to be ensured otherwise the visibility of the welding path will be a problem. The quality of the welding will not be up to the mark without this technique.
  • The filler metal should be kept at a distance from the tungsten electrode. Otherwise, there is a possibility of the contaminating the electrode. So filler should be kept at a very low angle.
  • The torch will be melting the base metal and the melted base metal will be performing the fusion of the filler metal. The tendency to melt the filler metal with the torch should be avoided.
  • The preparation of the tungsten electrode should be carefully done with the grinding wheel. It will be like sharpening the pencil. But for welding of the softer metal like Aluminium the tip should be flattened. The tungsten electrode tip just has to be touched against the grinding wheel.
  • You have to be very careful when welding the stainless steel. Too much heat can deteriorate the welding quality. The welding flame colour should be in the range flaxen to salmon. Too much oxidized dark greyish and dirty flame is undesirable. This colour resembles too much flame. With increasing travel speed and lesser current flow, the problem of overheating of the flame can be avoided. Reducing the diameter of the filler metal can also solve this problem.

Basic Principles of TIG welding

TIG welding Advantages in manufacturing

  • TIG is free from flux. So the TIG welded parts are totally free from corrosion. It is the very clean form of welding.
  • Metals like Aluminium are very delicate and care should be taken at the time of welding. Normal welding is not suitable for Aluminium as it is can deform the metal as a result of thermal stress generation.
  • TIG welding can be performed in any suitable positions- vertical, horizontal or overhead. Due to its general arrangement, it gives a better view to the welder to complete the job. You can complete the job within a very short time in comparing to the other welding processes.
  • Pressure tight joints like Gas pipelines can be welded with ease. TIG provides great strength with very negligible distortion.
  • It is a high-speed method and very clean with great precision. The quality of the welding is superb.
  • The electrode is non-consumable. So the welding is flawless as there is no need to change the electrode.
  • Thinner parts can be welded without any deformation. The finish is superior.
  • The welding can be done without the inclusion of the filler metal.

TIG Disadvantages

  • The filler deposition rate is very low in TIG welding method. As a result, it can be a slower process in comparison with electric arc welding.
  • As the welding is complicated, highly skilled technicians are needed to successfully complete the job.
  • GTAW produces intense rays of light which can be very dangerous for the eyesight of the welder or the surrounding people.
  • The initial cost of the machine and a man-power appointment can be high.
  • You cannot join thicker sheet metal parts with TIG welding.
  • TIG welding needs clean and tidy metal surface for a better weld quality. So surface preparation can be a time-consuming It can cost some money too.

TIG Application

  • TIG or GTAW is used frequently in welding lightweight aircraft. MIG almost serves the purposed of the TIG. But in case of lightweight aircraft manufacturing, you have to use TIG welding. Complex but light elements of the aerospace industry can be welded with TIG.
  • Stainless steel, Aluminium, high carbon steel, gold, bronze, nickel, copper and many unconventional metals can be welded in this process.
  • Automobiles work with sheet metals. The sheet metals welding of the automobile is done with TIG. The automotive vehicles have to endure a lot of stress in their lifespan. So the precision, as well as strength, is needed to be ensured. The welded joints are not rusted and also corrosion free.
  • Repairing tools without the trace of repair joints can be made by the TIG. Toys, Aluminium tools, metal parts, car parts all can be repaired through the TIG welding method.
  • The use of TIG is not limited to industrial works. It is also used in arts.

Using TIG or GTAW in your manufacturing plant depends upon the type of prototype or final product you are building. Advantages and disadvantages are there. A manufacturing plant needs to go through these points and act accordingly. TIG is high-quality welding with affordable price but at the same time, it needs a skilled technician and some preparation of the metal surfaces.

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casting process
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Casting – the Most Significant Manufacturing Processes for the Modern Manufacturers

by norwegianprototypes
written by norwegianprototypes

Manufacturing is the technique that converts the raw materials into finished goods through some continuous processes which involve special knowledge, manpower, equipment and machinery. Modern day manufacturing is not possible without having a good knowledge of these processes. A complete man-machine setup with the division of labour is involved in these processes. Almost any raw material can be converted into finished goods by means of these significant manufacturing processes. Modern day manufacturing is not possible without these processes –

  • Casting
  • Moulding
  • Forming
  • Machining and
  • Joining
  • Imaging and Coating
  • Additive manufacturing

Modern Casting Techniques

Different Types of Casting Processes Explained

Casting

Casting is a process of manufacturing in which molten metal is poured into the mould having the cavity of the desired shape. After the metal solidifies the total solid metal is taken out of the mould. This solid part is called the cast part or the casting. The final product is machined if necessary otherwise used as it is. With casting, you can make any finished goods of any shape. Different casting processes involve sand casting, die casting, centrifugal casting and lost wax casting. Each of the casting processes has their merits and limitation. Let’s discuss the different casting techniques.

casting process in manufacturing

Sand Casting

Materials of any melting point can be cast in the sand casting process. It is very cheap but to get desired finishing extra care should be taken. A typical sand casting process involves a furnace to melt the metal, the pattern and the sand mould. Generally, green sand with some natural binders is used to make the sand mould. Any kind of porosity in the sand should be removed. Proper ramming of the sand is necessary. The sand and the binder ratio should be accurate. Different types of sands are available for casting. Suitable sand selection is also a very important task in the process.

Advantages of Sand Casting

  • It is very cost efficient
  • Metals or alloys of any melting point can be used.
  • Any shape can be obtained.
  • Very less wear and tear of the pattern. The pattern used is also of very low cost as it is mainly made of wood.
  • Ferrous parts can be easily manufactured. Materials of the high melting point can be used.

Disadvantages of Sand Casting

  • Extra machining work is required in this process. After the metal solidifies some extra metal needs to be cut by machining process because of the runner and the riser shapes.
  • Surface finish is not always up to the mark.
  • Dimensional accuracy is difficult to achieve. The parts in which the dimensional accuracy is not that important can be easily manufactured by sand casting.
  • Materials may have low mechanical strength due to some faults in the casting technique as the process is totally manual.

 

Die Casting

Die casting is another casting method that involves permanent die. The die or permanent reusable moulds are used in die casting. As a result, the finished product is geometrically accurate in shape and dimension. It involves high pressure inside the casting chamber so the castings are accurate in size and shape. Mainly non-ferrous metal parts are manufactured in die casting method. Electrical equipment, motor parts, telecommunication materials, automobile parts and many other assembly parts are frequently manufactured using die casting.

Advantages of Die Casting

  • Manufacturers can get complex shapes with close tolerances.
  • It is suitable for rapid mass production. All the parts will have same dimensions and sizes.
  • Very less surface preparation is needed for making the castings.
  • The uniform design is one of the great features of die casting.
  • High mechanical strength is obtained by die casting

 

Disadvantages of Die Casting

  • It is not suitable for small-scale production.  To make the process cost-effective, the mass production of the materials is needed.
  • High initial cost of the materials and setup is observed.
  • There are some limitations of the dimensions of the finished goods. So goods having any dimensions and shapes are not suitable to manufacture in die casting.
  • Materials having lower melting points are only suitable for die casting.

Centrifugal casting

Centrifugal casting is another precision casting process. In centrifugal casting, the molten material/metal is poured into the spinning chamber. The chamber orientation can be vertical or horizontal. It depends on the size and shape of the product needed by the manufacturer. If the material is tubular then the horizontally rotating chamber is used. When ring-shaped materials are needed as the finished goods vertical chambers are used. Centrifugal castings are used for that parts that can symmetrically rotate on the same axis. For more knowledge about Centrifugal casting please visit the link:

Advantages of Centrifugal Casting

  • Excellent surface finish for the round shafts, tubes, cylinder and ring-shaped materials.
  • Excellent mechanical strength due to the fine-grained structure of the materials.
  • High production rates.
  • Hollow interiors in the products like tubes and rings can be done easily without the application of the core.
  • Lighter impurities.

Disadvantages of Centrifugal Casting

  • Not all metals are suitable for centrifugal casting.
  • The initial setup cost can be higher.

 

Lost Wax Method or investment casting

In investment or lost wax casting the molten metal is poured into the mould that is made of wax. It is also called the lost wax method. The wax patterns are prepared by injection moulding. The outer part is made of a harder shell. When the molten metal is poured, the wax is melted and drained away. The metal sample solidifies and finished good is obtained. Aerospace industries, computer parts manufacturers, food and beverage makers as well as jewellers are using lost wax methods.

Advantages

  • Superb intricate designs can be obtained.
  • Excellent surface finish is obtained and no parting line is present.
  • High accuracy can be obtained for the complicated designs.
  • Very less machining is required for the finished goods.

Disadvantages

  • It is a very costly process.
  • The parts that can be cast should be of very low weight.

These are some of the major casting processes involved in modern-day manufacturing process. For more knowledge have a look at the casting classifications.

 

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