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What Makes Cryogenic Deflashing Method a Cut Above The Rest?

November 16th, 2018 by

Before the final inspection and packing, moulded rubber parts must undergo a finishing process to remove excess flashes. “FLASH” is an excess amount of rubber that oozes out between the two halves of a mould during the moulding of rubber parts.

 

The flash occurs in areas where different sections of the mould join together and are called the ‘parting line flash’. The remaining part of the mould flash traces around where the different sections of the mould join together.

 

Flashes cannot be avoided no matter what technique has been used to manufacture these rubber products. While manufacturing high-performance materials for growing markets like electronics and automotive, intricate finishes, consistency and strict tolerance must be met.

 

Importance of Cryogenic Deflashing

 

 

This is the only method that makes it possible to eradicate complex flash at the inner dimensions. Parts with a thin flash can be removed through cryogenic deflashing quickly. The traditional deflashing methods generally deliver a poor deflashing effect as it is done manually with the help of blades, scissors or knives. The manual trimming method has a high variability in quality and the production rate due to the geometry of the parts. Since the finish quality is not up to the mark, it leads to high rejection rates. Unevenly deflashed products when used can affect and damage the machine it is used in.

 

The Process of Cryogenic Deflashing

 

 

Cryogenic Deflashing is a combination of rapid rotation, nitrogen and plastic blast media is used to get rid of the flash in an extremely precise and economical way. The rubber parts are arranged in a perforated container which is then inserted in a blast enclosure.

 

The containers rotate and evenly expose all sides towards the blast media. The enclosure is insulated with firm polyurethane foam for stable temperatures. The liquid nitrogen decreases the temperature inside and freezes the flashing to make it fragile.

 

With the use of pure nitrogen with zero moisture the requirement of a dryer is eliminated. A fast-moving impeller shoots the polycarbonate pellets in the container. These high-speed pellets trim the inner as well as the outer diameter flashing neatly in a single operation. The effective lubricity and hardness lessens the impeller’s wear and increases its durability.

 

Parting- line flash thickness determines the capability of the system to finish the moulded part in concurrence with the cycle time and LIN consumption. A thicker flash is more difficult to get rid of and requires lengthier deflash cycle time which results in higher LIN consumption. The optimum parting-line flash thickness is 0.001” to 0.005”. Optimum finish quality and LIN consumption are based on the mould design and condition.

 

 

Advantages of Cryogenic Deflashing

 

 

Cryogenic deflashing offers numerous advantages over other traditional or manual deflashing methods:

 

● This process maintains an element of integrity and precision and ensures greater productivity.

● Due to this using a batch process, the cost of per piece is lesser as the number of parts processed in a specific time increases. This makes the manufacturing process economical and cost-efficient.

● Repairing or replacing a mould rises up the expenses bracket. In this method, the moulds can bede-flashed which extends their durability.

● It delivers consistent results in every lot.

● This technique is completely non-abrasive.

● The entire procedure is highly automated which eliminates the need of a human operator.

● This method eradicates the use of any toxic chemicals and is enclosed to a minimum sound which proves it to be environmental-friendly.

 

Harkesh Rubber uses cryogenic deflashing which is the most advanced deflashing process, unlike most of the other OEM’s. This method polishes the parts (typically O-Rings) and minimizes any sign of the flash or parting line delivering an efficient and precise product.

 

With this process, we ensure precision and fulfill our commitment of delivering a quality product. This technique not only improves the performance of the product but also saves the time and effort invested which eventually reduces the cost of production as well.

   

Case Study – Special EPDM Compound Diaphragm for Aircraft Engine Application

October 4th, 2018 by

ABOUT THE CLIENT

The Client is an established Control Valve Manufacturer from America.

 

BUSINESS PROBLEM

 

The vendor who provided the rubber seals for the client for almost 5 decades was acquired by the competition. Since the vendor had to comply to military secrecy, they stopped sharing the information with the client regarding the base polymer, physical properties required, and other necessary details.

 

This put the client in a fix as they did not have the required details about the parts supplied by the vendor. They also needed to manufacture a special diaphragm to support a huge military account in the USA.

 

OUR SOLUTION

 

Harkesh Rubber came in contact with the valve manufacturer. Since we had the experience to meet their moulding requirement, we soon figured out the need to develop a suitable compound formulation for this application.

 

Once we took the feedback from the customer regarding the application and approval tests required, we determined that the compound needed to work in Aviation Turbine Fuel. After that, we selected the EPDM material for the application. We also reviewed the old material test certificates of the previous vendor and deciphered the special needs the compound would require, like the use of silicone oil and very high elongation.

 

RESULTS

 

With our analysis and research, we developed a special EPDM compound that was suitable for work in Aviation Turbine Fuel at high temperatures and with a work cycle in excess of 10,000 hours. We created diaphragm samples from the compound and supplied them to the client. They assembled the components and delivered them to the leading Aircraft Engine Manufacturer. Once the trials were conducted over a year, the diaphragm and the compound were approved.

 

BENEFITS

 

The client was able to retain their account with the leading Aircraft Engine Manufacturer.

 

Since 1982, we have built a reliable reputation in the rubber industry on our unique solution based approach that has made us the preferred partner for critical sealing solutions. We provide high precision, cost-effective sealing solutions for technically demanding applications.

   

Valve World Expo: The Biggest Valve Industry Affair Under One Roof!

August 1st, 2018 by

The Valve World Expo is the biggest ground to showcase and encounter the experts from the valve industries around the world. It is a one-stop shop that will assemble many great minds and act as a platform to meet proficient valve industrialists who will display their products at a large scale. It is a substantial interactive platform that focuses on individual communication. Valve World Expo brings together valve expertise from the:

 

● Oil, Gas, Petrochemical, and Chemical Industry

● Food Processing Industry

● Marine and Offshore Industry

● Water and Waste Water Management Industry

● Automotive and Machine Construction Industry

● Pharmaceutical Industry

● Power Generation Industry

 

The Valve World Expo is undoubtedly the most prestigious event for anyone who uses valve technology in their business.

 

Harkesh Rubber has been serving the valve needs for all kinds of engineering industries for the past 35 years. Our services employ a combination of well-established product mastery and ingenious engineering. What makes us idiosyncratic are the custom-made solutions we provide with optimum quality service.

 

We, at Harkesh Rubber, are experienced at fulfilling the technical merchandise requirements for multiple industries within strict timelines. With a reputation for excellence around the world, we have served clients in Asia, Europe, the Middle East, the USA and many other countries.

 

We provide expert solutions for:

 

Rubber Diaphragms

 

The Rubber Diaphragm is a multifaceted tool that is used as a sealing agent between two elements. It has a huge demand in industries like power generation, aerospace, chemical and process, and more.

 

O-Rings

 

O-Rings have a variety of purposes in different application areas. They are used to stop the air from passing between the two ends. They are available in various metric and inch standard sizes. O-Rings are commonly used for plumbing purposes, automobile requirements, air-conditioning technology, and more.

 

Seals

 

The seal is used in rotary shaft equipment to keep dust, dirt, oil or any other contaminants out while keeping it lubricated. The sealing element, the metal case, and the spring are what form the oil seal.

 

Gaskets

 

We are well-renowned for the production of custom-made rubber gaskets. They are used to prevent leakage between two articles under compression. These gaskets are made to withstand and handle extreme pressure and wear.

 

Harkesh Rubber is proud to exhibit at Valve World Expo 2018. The event will be held from the 27th-29th November 2018 in Düsseldorf, Germany. Make sure to visit our booth, located at Hall 4 / F22 at the venue!

   

Case Study – Diaphragms for Control Valves

July 27th, 2018 by

About the client

 

The Client is a leading control valve manufacturer based in Germany.

 

Business Problem

 

The client was not happy with their existing diaphragm supplier due to consistent delays in supplies. The supplier’s delivery cycle time was higher than the valve manufacturing cycle time, resulting in delays and production loss.

 

Our Solution

 

Harkesh Rubber offered to develop one of the diaphragms for life cycle tests. Initially, the client’s team was a little skeptical. However, they agreed to the testing. We developed the first batch of diaphragms which were put to test simultaneously with diaphragms manufactured by their existing supplier.

 

Results

 

After two weeks of testing, while our diaphragm was in perfect working shape. At the same time, the diaphragm from the existing supplier had to be replaced. While our first diaphragm was still in good shape after 1.2 million cycles test, the existing supplier’s second diaphragm too was worn out. The client switched the entire range of diaphragms to Harkesh Rubber after the successful testing.

 

Benefits

 

● 25% reduction in diaphragm delivery cycle time

● 20% reduction in diaphragm purchase cost

 

Since 1982, we have built a reliable reputation in the rubber industry on our unique solution-based approach that has made us the preferred partner for critical sealing solutions. We provide high precision, cost-effective sealing solutions for technically demanding applications.