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Author Archives: Andrew Lewis

  1. Punch and Shear Transformer Core Material

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    In metal fabrication, punching and shearing are two distinct metalworking procedures. Metal punching is a cutting technique in which the material is removed from a metal sheet by exerting sufficient tearing power. On the other hand, metal shearing removes excess material from sheet metal without using heat or generating waste in the form of chips.

    Punch and shear processing devices are metal fabrication machines that combine the functionalities of punching and shearing equipment. Typically, they are used to cut shapes and punch holes into metal sheets simultaneously.

    In this article, we will take a deeper look at one of AIM Joraco’s projects which focuses on punch and shear applications.

    AIM Joraco’s Punch & Shear Application Using Servo-Driven Feeder

    AIM Joraco designed and constructed a highly automated multi-press punch and shear system to produce transformer core sheets. The project’s objective was to achieve precise tolerances of 0.002 in. around the burr of the punched hole in the steel sheet. Moreover, the client generally used the system in electrical transformers.

    Engineers designed, fabricated, and rigorously tested the punch tools to ensure dimensional accuracy in the stack core transformer design for the client. Various in-house tests were also conducted to confirm that the tools consistently generated holes of the desired size and shape.

    AIM Joraco delivered this automated fabrication technology with a set of carbide tools that we precisely honed. Due to carbide’s ability to keep its cutting edge even during high-speed punching, the tooling achieves exact tolerances and delivers accurate components during long production runs.

    Capabilities Applied and Processes

    To achieve the exact tolerances required, AIM Joraco applied the following processes:

    • Punching: Metal punching stamps a shape onto a surface via pressure or percussion using a steel punching tool. This method removes material from a metal sheet by exerting sufficient cutting power.
    • Shearing: Metal shearing cuts through a metal sheet using a blade attached to a tool or machine. A squaring arm controls the placement of the cut, allowing a metal sheet to be placed in a precise area.
    • Servo Feeding: The servo feeding process uses a machine motor that powers the feed roller via a synchronous belt wheel. It also utilizes the release signal supplied by the punch cam to discharge the generated error through the cylinder.

    Equipment Used To Manufacture and Overall Dimensions

    The following machines and devices are used to fabricate the multi-press punch and shear system:

    • 2x Toggle Aire 2530 Press: The Model 2530 Press from AIM Joraco has a repeatability of 0.001 inches and can cycle up to 80 strokes per minute — faster cycle times with shorter-than-standard strokes.
    • Carbide Tooling Package: The precision-sharpened carbide tooling package enabled the system to create accurate components across extended production runs while preserving its cutting edge.
    • Servo Motor: A servo motor is a rotary or linear actuator that permits exact control of position, velocity, and acceleration. It consists of an efficient engine coupled with a position feedback sensor.

    The overall part dimensions of the system are 29.5 in. (width) x 30.75 in. (depth) x 63 in. (height).

    Partner With AIM Joraco for Custom Automation Systems!

    AIM Joraco has over 70 years of service experience, allowing us to provide presses that satisfy various specific requirements. We produced the TOGGLE-AIRE®, DIRECT-AIRE®, and HYDRO-AIRE® lines of pneumatic and manual toggle presses, semi-automatic rotary indexing machines, and assembly and fabrication tooling.

  2. Clean Room Presses

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    AIM Joraco provides diverse solutions with its benchtop pneumatic presses for clean rooms. The company’s goal is to meet the ever-demanding clean room standards while remaining the number one provider for toggle press. We manufacture TOGGLE-AIRE®, DIRECT-AIRE®, and HYDRO-AIRE® precision pneumatic and manual toggle presses for various applications.

    What Is A Clean Room?

    A clean room is a secure and controlled environment where critical components are manufactured. They are required in the pharmaceutical industry, nanoelectronics, and biotechnology to eliminate possibly hazardous toxins or compounds from the products or equipment. Clean rooms are also needed in industrial applications that demand an uncontaminated working environment.

    Clean Room Press Specifications

    AIM Joraco’s clean room press series specifications include the following:

    • Particle density for a particle of 0.3 µm or larger is less than 3.5 particles
    • Press noise silencing effect of 40 dB (A) or more
    • PTFE – No Lubrication Bearing Surface
    • 400 Series Stainless Steel (includes all fasteners, ram, and precision ground platen)
    • Internally contained lubrication for ram

    Clean Room Press Attributes

    AIM Joraco also offers the following press attributes:

    Compliance Equivalent to Class 100

    An ISO 5 Class clean room, also identified as a Class 100 clean room, is a manufactured structure with soft or hard-sided walls that use High-Efficiency Particulate Air (HEPA) filtration systems. HEPA systems are required to maintain air cleanliness levels of up to 100 particles (≥0.5 µm) per cubic meter of the inside air.

    Quiet Operation (Noise Level Reduction of 40 dB (A) or More)

    The noise level should not exceed 60 dB (A) in a laminar clean room and 65 dB (A) in a turbulent one. AIM Joraco developed a clean room press that meets and reduces noise standard levels.

    Lubrication-Free Wear Services

    Clean room lubricants require specially distilled oils to remove the more volatile, lighter particles that may evaporate quickly. In addition, some standards require special thickening agents that do not contain metals, reactive compounds, or other large particles.

    Stainless Steel Construction

    Stainless steel is known to be sturdy and can withstand the most rigorous cleaning process. Mainly, Grade 304 stainless steel is unreactive to most acids and alkalis, which aids in the prevention of corrosion-related contamination.

    Ram Wiper System

    Clean room wipers differ from regular wipers because they contain less lint to protect against pollutants. They also have greater absorption capacity, resistance to chemicals and abrasion, and better cleaning capabilities. AIM Joraco provides a press series with an upgraded wiper system for various applications.

    Other options include the following attributes:

    • Element Service Indicator
    • Adjustable Output
    • Filter, Regulator, Lubricator (FRL) – Clean Room Compliance
    • Dwell Timer
    • Non-Rotating Ram
    • Adjustable Ram Speed Control
    • Optical “No-Touch” Anti-Tie Down Actuation
    • Special FDA Powder Coat Finish
    • Clean Room Guarding, Bevel, and/or Sealants

    Markets Served With AIM Joraco’s Clean Room Press

    The mission of AIM Joraco is to provide superior-quality presses to various markets and industries. The following are four industries the company is targeting:

    Pharmaceutical Industries

    Pharmaceutical manufacturing necessitates a high degree of cleanliness and germ-free environments. Clean rooms can provide streamlined processes wherein products are protected from contaminants, such as dust, airborne pathogens, and atmospheric emissions.

    Life Sciences Industries

    A clean room is a functional necessity in the life sciences industries. It is vital to control any particulate and microbial contamination to ensure the product or output quality. Additionally, preserving the highest quality standards possible guarantees high efficiency and reputation.

    Regenerative Medicine Industries

    A strict clean room and clean room press are required to maintain the quality of cell-based medicinal products since the process involves living drugs.

    Surgical Industries

    All surgical industries use clean room technology to reduce airborne contaminants and maintain an antimicrobial setting in securing the safety of both patients and surgeons.

    Applications of AIM Joraco’s Clean Room Press

    Aside from the standard applications of clean rooms and clean room presses, some uses of AIM Joraco’s press include the following:

    Tissue Cutting/Sampling

    Clean rooms are constrained areas where filters and cleaning can control particle count and microbiological levels. This minimizes microbial contamination and prevents contamination levels from rising during tissue cutting and sampling.

    Implant Assembly

    Implant placement requires a high level of sanitation to avoid potentially dangerous infections caused by contamination. Clean rooms also help to reduce implant failure and disease progression by maintaining hygiene during the assembly process.

    Medical Device Assembly

    Medical device fabrication is a highly controlled industry in which companies strive to create quality products without endangering a patient’s health. They are designed for use in healthcare settings where hygiene and the need to prevent contamination are of the utmost importance.

    AIM Joraco: The Best Toggle Press Innovator

    Thanks to our 70 years of service experience, AIM Joraco provides quality presses that meet a wide range of special requirements! Tell us your project specifications, and we can quote a custom solution for your application.

  3. Compaction of Explosive Powders

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    Powder compaction is gradually becoming an essential industrial manufacturing technique for producing components with complex shapes and structures. It is the process of tamping powder particles in a die using high pressures. The tools are typically held vertically, with the punch tool forming the bottom of the chamber. After that, the powder is compacted into a shape and ejected from the cylinder.

    A powder compacting press compresses granular and powdered raw materials into various standard and custom-shaped units. It can suppress a wide range of products with high product density specifications and can compact multiple pieces at once, making it ideal for large production industries. In addition, the press requires innovative integrated machines, electricity, liquid, and gas control, as well as an automatic feeding and discharging device.

    This article will discuss the different types of powder compacting presses and the product developed by AIM Joraco.

    Types of Powder Press Machines

    The four most common types of press machines used to compact powder material are as follows:

    Hydraulic Press

    A hydraulic press generates compressive force by using a hydraulic cylinder. It is appropriate for the industries of carbides, powder metals, ceramics, polymers, and other particulate materials. Furthermore, hydraulic presses are commonly used in factories that manufacture powder products.

    Mechanical Press

    Mechanical presses are frequently used in manufacturing technical ceramics, but they are also well-suited for other commercial processes. Compared to hydraulic press machines, mechanical powder presses have limited maximum compaction forces that are typically greater than or equal to 5000 kN.

    Electric Press

    Electric powder presses are servo-powered machines that compress materials at extremely high pressures. Because of their servos, they can regulate the placement and response time of the output shaft instead of keeping a constant press cycle speed. Moreover, electric metal presses can perform several functions and use a closed-looping feedback mechanism to enable a more precise cycle rate and load regulation.

    Isostatic Press

    Isostatic presses enable users to produce uniform-density components using a dry bag design, simplifying and improving powder filling, compaction, and ejection. These machines are typically used in ceramics, carbides, composite materials, pharmaceuticals, and explosives.

    AIM Joraco Compacting Press

    AIM Joraco developed a compacting press for the world’s leading provider of technology for the oil and gas industry. It is the outcome of the need to design an explosion-proof mechanism with an integrated safety capacity. It must also adhere to industry standards, legal requirements, and the company’s clear and specific guidelines.

    The company designed and built this compacting press entirely in-house. This included reinforced machine guarding, a robust protection system, integrated safety features for operators and equipment protection, and a process control system for capsule consistency.

    Capabilities Applied

    The following are features highlighted in the developed compacting press:

    • Compacting: The press is intended to pack explosive substances into capsules for oil well-perforating processes.
    • Force Monitoring: The force monitoring system determines the compaction work of delicate substances and reinforces the proper press operation. It also offers control signals, alarm systems, real-time inspection, and quality assurance data recording.

    Equipment and Specifications

    Direct-Aire® Model DA-400T is an AIM Joraco benchtop pneumatic press with a capacity of 2300 lbs. of force. It includes a straight pneumatic cylinder for applications that require full force throughout the stroke.

    The overall part dimensions are 13 in. (width) x 18 in. (depth) x 42 in. (height) for the press and enclosure.

    Choose AIM Joraco for Your Compacting Application

    AIM Joraco’s competitive success and reputation in the benchtop pneumatic press industry allow us to consistently offer our customers solutions that provide accurate results. Contact us for more information about this project or our custom pneumatic press-building capabilities!

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