The tungsten carbide is an alloy which has the main component of powders including tungsten carbide, titanium carbide and metal powder such as cobalt, nickel, etc, as an adhesive, obtained through the powder metallurgical method. It is mainly used to make high-speed cutting tools and hard, tough material cutting edges, and high wear parts for fabrication of cold dies, measuring tools.

Mechanical And Physical Properties Of Tungsten Carbide

1.Wear resistance

The wear resistance of the tungsten carbide is its most important feature. In practical applications, carbides are 20-100 times longer than some wear-resistant steel alloys.

2.Bending resistance

The sintered carbide has a high elastic modulus and the smallest bend is obtained when subjected to bending force.

3.Corrosion resistance

It is usually used in many chemical and corrosive environments because carbides are typically chemically inert.

4.Torsional strength

The amount of torsion is two times than the high-speed steel and the carbide is the preferred material for high-speed operation applications.

5.Compressive strength

Some grades of cobalt carbide and cobalt have perfect performance under ultra-high pressure and is very successful in pressure applications of up to 7 million kPa.

6.Toughness

Cemented carbide grades with high binder content have excellent impact resistance.

7.Low temperature wear resistance

Even at an extremely low temperature, the carbide remains good to wear resistance and provides relatively low friction coefficients without using a lubricant.

Applications Of Tungsten Carbide

Cutter tool

Tungsten carbide cutter tool is the widest application, used for making lathe tool, milling cutter, planner tool, drilling bit, etc. Among them, the tungsten cobalt carbide is suitable for black metal, non-ferrous metals, processing of non-metallic materials, such as cast iron, cast brass, colloidal wood, etc. Tungsten titanium cobalt is suitable for long chip processing of steel and other black metals. In the same alloy, what has more cobalt content suitable for rough machining, what has less cobalt content suitable for fine machining.

Mold material

The cemented carbide is mainly used for cold wire drawing dies, cold stamping dies, cold extrusion dies, and other cold work molds.

Under the wear-resistant working conditions of the impact or strong impact, the tungsten carbide dies are required to have good anti-polishing toughness, fracture toughness, fatigue strength, bending strength, and good wear resistance.

In general, the relationship between the wear resistance and toughness of the carbide is contradictory, the increase in wear resistance will result in a decrease in toughness, and the increase in toughness will inevitably lead to a decrease in wear resistance. Therefore, when choosing a tungsten carbide grade, it is necessary to meet specific usage requirements based on the processing objects and machining conditions.

If the selected grade is easy to produce early cracks and damage, it is advisable to use the grade with high toughness. If the selected grades are easily damaged as the wear, it is appropriate to choose a grade with a higher hardness and better wear resistance.

Measuring tool and wear parts

The tungsten carbide is used in the easy to wear surface inlay and parts of the measuring tool, grinding machine precision bearing, the wear parts such as guide plate and guide rod of centerless grinder, lathe center.

Heat Treatment Of Tungsten Carbide

The hear treatment process of tungsten carbide can be divided into four basic stages

1.Removal of the molding agent and the pre-sintering

In the initial stage of sintering, the molding agent gradually decomposes or vaporizes, excluding the sintered body, while at the same time, molding agents carburize sintering and the amount of carbon will vary depending on the type, quantity and the sintering process. The powder surface oxide is reduced, and hydrogen can reduce oxides of cobalt and tungsten at a sintering temperature. When the reaction between carbon and oxygen is not strong, the contact stress between the powder particles is gradually eliminated. The bonding metal powder begins to generate reply and recrystallization and the surface diffusion begins to occur. The strength of the block is improved.

2.The solid phase sintering stage (800°C – eutectic temperature)

In the presence of the liquid phase, in addition to the process of continuing the previous stage, solid-phase reactions and diffusion exacerbating with plastic flow enhancement, and the sintered body appears obvious contraction.

3. Liquid phase sintering stage (eutectic temperature – sintering temperature)

When the liquid phase of the sintered body occurs, the contraction is quickly completed and then a crystallization transition is generated. The basic organization and structure of the carbide are formed.

4.Cooling stage (sintering temperature – room temperature)

At this stage, the organizational and phase components of the tungsten carbide have certain changes with the different cooling conditions, which can utilize this feature, heat treatment of the cemented carbide will improve its physical-mechanical performance.

High performance tungsten carbide has excellent mechanical and physical properties including high wear resistance, corrosion resistance, bending strength, torsional strength, etc, widely used for the making of cutter tools, cold mold, wear parts, etc. The article also briefly introduces the four basic stages of tungsten carbide heat treatment which can improve physical mechanical performance of the cemented carbide.

Tungsten carbide precision part machining technology is more and more widely adopted. It is essential and important in the precision part factory. The article mainly introduces useful knowledge about carbide precision part processing, such as four preparation work, heat treatment of the precision parts.

Four Preparations Must Be Done For Machining Tungsten Carbide Precision Part

There are three preparation stages when performing carbide precision parts machining.

1.Preparation stage

Before the precision machining of tungsten carbide, you need to analyze the pattern of processing parts, then determine the machining scheme, such as a process, selecting machine tool, processing cutting volume, tool, fixture, etc, and calculate the coordinate value of the tool path. It is worth spending some time for these necessary preparations, which can make your tungsten carbide parts machining are more smoothly completed.

2.Programming stage

After getting the process route and drawings, we need to write a CNC machining program language describing the processing based on the processing technology information, which can be identified by the system. Do a good job in programming, which isone of the key steps for precision parts machining.

3. Machining stage

When the program is executed, the machine tool system decodes, registers, and calculates the program, and sends a motion command to the machine servo mechanism, driving the moving parts of the machine tool automatically completing the precision parts processing.

The above three preparation stages are the indispensable steps before processing precision parts, which is a process from the drawing to the machining.

Points For Attention In Heat Treatment Of Tungsten Carbide Precision Part

In order to improve the performance of tungsten carbide precision parts, material cutting performance and eliminate the internal stress of the workpiece, some heat treatment procedures should be arranged in the machining process.

1. Preparatory heat treatment

The purpose of pre-heat treatment is to improve the cutting performance of the material, eliminate residual stress during blank manufacturing. Commonly used methods include annealing, normalizing.

2. Eliminate residual stress

Since the internal stress generated during the fabrication of the blank will cause the workpiece to deform and affect the machining quality, heat treatment must be arranged to eliminate residual stress. The best arrangement of the heat treatment for eliminating residual stress is after rough machining and before fine finishing. For parts that do not require high precision, annealing is usually performed before the blank enters the workshop to eliminate residual stress. For high-precision cemented carbide parts, such as precision screws, precision spindles, multiple heat treatments should be arranged to eliminate residual stress, and even ice-cold treatment is often used to stabilize size.

3.Final finish

The purpose of final processing is to increase the strength, surface hardness and wear resistance and is usually performed prior to grinding of tungsten carbide precision parts. Commonly used are quenching, carburizing, nitriding and carbonitride.

Therefore, in the tungsten carbide part machining, in order to improve the mechanical properties of the precision parts, heat treatment is essential, so that the processing quality conforms to the product requirements.

Cutting is one of the common methods used in a tungsten carbide rod, carbide sheet and cemented carbide wire. For cutting the material of 1 mm or less, diamond ultra-thin cutting pieces are commonly used for machining.

The diamond resin matrix cutting piece, wherein the outer ring belt is a resin binding agent abrasive working layer, and the central portion is a high-strength metal, mostly for medium, large cutting slots and cutting.

During the tungsten carbide machining, the cutter tool itself must be higher than the hardness of the machined workpiece. At present, the cutting tool materials for turning tungsten carbide parts are mainly made of high-hardness high-resistant non-metallic adhesive CBN and the diamond PCD.

1. The tungsten carbide components which have a hardness of less than HRA90, select the BNK30 material CBN tool to carry out a large amount of turning and the tool is not broken. The carbide components which have a hardness greater than HRA90 generally select CDW025 Material PCD cutter tool or grinding with a diamond grinding wheel adopting a resin binding agent.

2.To process R3 groove or more of the carbide precision parts, for large machining allowance, generally adopts BNK30 CBN tool for roughing processing, then grinding with grinding wheels. For small processing margins, the grinding can be done directly with wheels , or adopting PCD tool for flush processing.

3.When the crescent groove rib of the tungsten carbide roller is processed, the CDW025 diamond carving milling cutter tool also known as rotary milling cutter is adopted.

For the milling process of carbide parts, according to customer needs, CVD diamond coating milling cutters and diamond insert milling cutter can be provided to perform tungsten carbide precision parts machining, which can replace electrolytic corrosion technology and electric spark process, improving production efficiency and product quality, such as a CVD diamond coating milling cutter to micro-milling the cemented carbide, and the surface roughness can reach 0.073 μm.

What Are The Factors Affecting The Machining Accuracy Of Tungsten Carbide Part

1. Machine tool error

The machine tool error refers to the manufacturing, installation errors and wears of machine tools. It mainly includes guide error of machine tool guide rail, machine tool spindle rotation error, transmission error.

2. Machining principle error

The machining principle error refers to an error generated by adopting the approximate blade profile or approximate transmission relationship for machining. The principle error often occurs in a thread, gear, complex surface machining.

3. Residual stress inside the workpiece

The residual stress is generated during the blank manufacturing, heat treatment process, cold strengthening and cutting processes.

4.Machining environment

The machining site often has many small chips. If there is a part locating surface or location of locating hole, which affects the processing accuracy of the parts, for high-precision processing, some small particles will affect the accuracy.

5.Manufacturing error and wear of the fixture

The error of the fixture is mainly referred to as the manufacturing error of positioning elements, tool guiding elements, an indexing mechanism. The fixture is assembled, with the relative dimensional error between the various components and worn on the working surface during use.

6.Manufacturing errors and wear of tools

The influence of tool error on machining accuracy varies according to the type of tools.

7.Thermal deformation of the processing system

During the machining process, due to the internal heat source, such as cutting heat, frictional heat or an external heat source such as temperature, heat radiation, the processing system is modified, thereby affecting the machining accuracy. In large workpieces and precision machining, the processing error caused by the thermal deformation of the processing system accounted for 40% -70% of the total processing error.

For more detailed information, please visit the article page of tungsten carbide precision part machining technology.

Chinese Aluminum Circle has been commonly used in the auto industry with the advancement of science and technology and the development of industry, the end of the 19th century and the beginning of the 20th century, rims, hubs, and spokes began to be integrated through the casting process.

Later, people who love beauty invented something called a hub cover, which is generally made of plastic and covered on the outer layer of the steel hub. I think the wheel cover was originally intended to “conceal the ugliness”, but it was later found to be pretty, called “beautification”. Now, aluminum alloy wheels have become the mainstream, and the wheel cover has a higher level of meaning: “pretend”. In this regard, some Japanese cars are more advanced, such as the “Tiida”. If not a careful look at it, you would think they are aluminum-alloy wheels. If you want to buy a real one, you must buy the top version. It can also be explained that aluminum alloy wheels are indeed better than iron ones. So why are aluminum Circles so irreplaceable for cars?

The Advantages of the Aluminum Circle in the Auto Industry.

The car is the external manifestation of the owner’s personal image, and the rim and tires largely affect our first impression of the vehicle. No matter how beautiful the car is, if it is paired with dull, rusty rims, it will greatly reduce our impression of the car. The most eye-catching feature of aluminum alloy wheels is their appearance. The unique metallic luster of aluminum alloy and diversified shape design perfectly enhance the appearance of the car. Compared with steel wheels, aluminum alloy wheels have the following characteristics:

• Lightweight: Compared with steel and iron wheels of the same specification, each is about two kilograms lighter, which greatly reduces the weight of the car body and reduces the frictional resistance when the wheels are rolling, making the vehicle start faster and lose more power. Less, more fuel-efficient, energy-saving, and reduce environmental pollution.
• High strength: High strength and lightweight are linked together, to be precise, it should be greater than the specific strength. While, the same weight, the aluminum alloy wheel is much stronger, and has the same strength, the aluminum alloy wheel is much lighter. The high hardness of the aluminum alloy rim significantly reduces the deformation of the circle when turning. This is especially important for cars equipped with high-performance tires.
• (3) Good elasticity: Improve the ride comfort of the vehicle, and it is easier to absorb vibration and noise in motion.
• (4) High precision: The aluminum alloy wheel rim has high machining precision, precise geometric dimensions, small yaw runout, and good balance. The high concentricity makes the car run smoothly and fuel-efficiently under reasonable force; the high roundness can improve the wheel movement accuracy, which is beneficial to high-speed driving and steering.
• (4) High precision The aluminum alloy wheel rim has high machining precision, precise geometric dimensions, small yaw runout, and good balance. The high concentricity makes the car run smoothly and fuel-efficiently under reasonable force; the high roundness can improve the wheel movement accuracy, which is conducive to high-speed driving and steering.
• (5) High recovery rate The aluminum alloy wheels can be recycled 100%, which is an environmentally friendly product.
• (6) Good heat dissipation. Aluminum has greater thermal conductivity than steel, and aluminum alloy wheels can conduct the heat generated by braking faster. In addition, the unique shape of many aluminum alloy wheels makes them act as a cooling fan for the brake components during high-speed rotation, which increases the life of the tires and has certain benefits for the cooling of the brake system, especially for cars on highways. The effect is more obvious when driving between downtown and downtown.
• (7) Corrosion-resistant and beautiful aluminum alloy wheels are specially treated to prevent rust and corrosion and can maintain a long-term bright feeling. Aluminum alloy wheels have a variety of designs, plus the effect of gloss and color, which also improves The car’s noble sense of value and aesthetic atmosphere.
• (8) Good operational performance. The aluminum alloy wheel rim is light in weight and has good roundness. It can control the steering wheel as you like. When turning, it is light and flexible, braking is easier, and the operation is light and easy.

If the automobile steel rim is compared with the aluminum rim, of course, the aluminum rim is better. The reasons are as follows:

The characteristics of aluminum are softer than steel, which determines that the comfort of aluminum rims is better than that of steel rims;

The heat dissipation of the aluminum rim is about 3 times that of the steel rim so that the tire system is always at a relatively comfortable temperature and prolongs the service life of the tire;

For the aluminum circle of the same size, aluminum is lighter than steel. The most intuitive advantage is to reduce fuel consumption.

Aluminum foil with excellent performance is gradually replacing the application of copper foil in various fields, promote the substitution of copper with aluminum strip, will be able to better use of aluminum resources, copper resources.  And aluminum foil basically replaced copper foil, and achieve the same performance.  

Today, by reading this article, you can learn about several important products of aluminum foil.

Pharmaceutical Aluminium Foil

There are several types of pharmaceutical aluminium foil, such as pharmaceutical aluminium foil, pharmaceutical PTP aluminum foil, pharmaceutical packaging with PTP aluminum foil, PTP aluminum foil. The material of pharmaceutical aluminium foil requires high precision printing, rich color and clear pattern. And it is required that the plain foil can be printed online on the automatic drug blister packing machine. In addition, it also requires good moisture permeability, moisture resistance, oxygen resistance, sealing with molding materials, can avoid light, incense. Using aluminum foil as the base material, easy to open or break, convenient for consumers to take.

Air Conditioning Aluminum Foil  

Air conditioning foil is a special material for making heat exchanger fins for air conditioners. The air conditioning foil used in the early stage is a plain foil.  In order to improve the surface performance of plain foil, anticorrosive inorganic coating and hydrophilic organic coating were applied before forming to form hydrophilic foil.  At present, hydrophilic foil accounts for 50% of the total amount of air conditioning foil, and its use proportion will be further improved.  In addition, there is a hydrophobic foil, so that the fin surface has a hydrophobic function, to prevent condensation water adhesion.  Because the technology of improving surface defrost of hydrophobic foils needs to be further studied, the actual product is very few at present.

The thickness of the air conditioning foil is 0.1mm ~ 0.15mm.  With the development of technology, air conditioning foil has a tendency of further thinning. The thickness of leading products in Japan is 0.09mm now.  In the very thin state, aluminum foil to have good formability, its structure and performance must be uniform, metallurgical defects less, small anisotropy, and requires high strength, good ductility, uniform thickness, good flatness.  The specifications and alloys of air conditioning foil are relatively single, which is suitable for large-scale production. However, the market is seasonal. For professional manufacturers of air conditioning foil, it is difficult to solve the contradiction between short supply in peak season and almost no demand in the off-season.  

Driven by the strong market demand, the production capacity and technical level of air conditioning foil in China have been continuously improved in recent years, and now a group of large, medium, medium and low production enterprises has been formed. The product quality of some large enterprises, such as North China Aluminum and Bohai Aluminum, has basically reached the international advanced level.  Due to excess domestic production capacity, the market competition is extremely fierce.  

Cigarette Packaging Aluminum Foil  

Our country is the world’s largest cigarette production and consumption power, at present, our country has 146 large cigarette factories, an annual output of 34 million large amount of cigarette box, basically using cigarette foil packaging, 30% by spraying foil, 70% use rolling aluminum foil, aluminum foil rolling consumption of 35000 tons, with improvements in people’s health consciousness and imported cigarettes,  The growth of cigarette foil demand has slowed down significantly and is expected to increase slightly in recent years.  China’s cigarette packaging foil accounts for 70% of the total amount of double zero foil, at present, there are two or three domestic enterprises that can produce high-quality tobacco foil, the technical level is equivalent to the international level, but the overall quality of domestic tobacco foil has a certain gap with the international level.  

Cable Aluminum Foil  

Cable foil is an aluminum composite foil composed of plastic film on one or both sides, which is used as the shield of the cable by taking advantage of the airtight and shielding property of aluminum foil.  Cable foil requires less oil on the surface, no holes, high mechanical properties, the overall quality is not high, but the length is very strict.

Decorative Aluminum Foil 

Decorative foil is a decorative material applied in the form of aluminum-plastic composite, which takes advantage of the characteristics of good coloring and high photothermal reflectivity of aluminum foil.  Mainly used for construction, furniture decoration and part of the gift box packaging.  The application of decorative foil in China’s construction industry began in the 1990s, and it has spread rapidly from Shanghai, Beijing, Guangzhou and other central cities to all parts of the country. In recent years, the demand has increased sharply. It is generally used as decorative materials for the inner wall of buildings and indoor furniture, and is also widely used in the facade and interior decoration of commercial institutions.  

 Decorative foil has the advantages of heat insulation, moisture-proof, sound insulation, fire protection and ease to clean, and the appearance of luxury, convenient processing, construction and installation speed.  At present, China’s construction, home decoration industry has formed a decorative foil application boom.  With the rapid development of China’s construction industry and the continuous popularity of decorative foil application, decorative foil demand will increase greatly.  In addition, the use of decorative foil packaging gifts is very popular in foreign countries, in recent years in China’s rapid development speed, is expected to have a better prospect.  

When the composite packaging film is produced, the composite method can be divided into extrusion composite, dry composite, wet composite, solventless composite. The most used methods are dry composite and solvent-free composite. What are the differences between the dry composite and solvent-free composite, and can be used for which type of packaging respectively?

Composite Method And Applications

Solvent-free Composite

The solvent-free composite film is different from dry composites that do not use organic solvents, which not only avoids the environmental pollution caused by organic solvents volatilization, but also does not require dry operating work segments, directly reducing production costs, and eliminating the influence of solvent and high temperature drying on the composite substrate, so that the size of the packaging film is more stable.

Dry composite

Dry composite is a kind of composite method. The adhesive is evenly coated on the substrate film by the roller. After dried, The composite film was synthesized by pressing and sticking on the composite part. The dry composite packaging film has a wide range of applications, with excellent chemical dielectric erosion performance, mostly used in packaging containing alkali, spicy, oil, etc., which is also suitable for cosmetic flavors, emulsifiers, especially for the high-temperature cooking packaging, very advantageous.

Coating Method

Solvent-free Composite

1. Multi-roller transfer coating

2. Thin adhesive layer, uniform thickness

3.The amount of coating is mainly determined by each roller speed, which can be adjusted online.

Dry composite

1.Concave roller coating

2.Thick adhesive layer, with a concave-convex shape, uneven thickness.

3.The amount of coating is mainly determined by the number of concave rolls, and the adjustment is limited only through replacing the convex rolls.

Glue Film And Compound Fastness Formation

Solvent-free Composite

1.low initial adhesion

2. The glue film and composite fastness are basically formed during the process of curing.

3. The glue film formation is mainly a chemical process of two components.

Dry composite

1.Heated through the oven, high initial adhesion.

2. The glue film and composite fastness are mainly formed on the machine, and the curing process only plays an auxiliary role.

3. The glue film formation is mainly a physical process for drying volatile and composite pressure.

Dry And Cooling

Solvent-free composite

1.No need to dry

2.Single component glue needs to cool, double-component glue generally does not need cooling.

Dry composite

1. The necessary step

2. Drying is usually under high temperature, and the drying temperature and cooling temperature of each segment have a large impact on the composite.

Curing

Solvent-free composite

Curing is the key process of solventless composite. Effect of curing temperature and time on two-component adhesive, which will have an influence on composite quality.

Dry composite

Curing usually is the auxiliary process and temperature and time have a certain effect on composite quality.

These two packaging composite have their own advantages. For choosing which composite method, should refer to the properties, weight of the packaging content. Although there are still many problems to be solved for solvent-free composite , it surely has advantages in health, safety, environmental protection, and cost.

In recent years, with the increasing environmental protection awareness, solvent-free laminating adhesives are more widely used in the flexible packaging industry. This article will introduce the advantages, problems and development trends of solventless adhesives..

Advantages Of Solventless Adhesives

1.Environmentally friendly

Solvent-free laminating composite adopts solventless adhesive, which will not volatilize VOCs nor produce any irritating odor. It solves the problem of residual solvents in the packaging, eliminating the erosion of the organic solvent on the printing ink, can also achieve cleaning production, conducive to environmental protection.

2. Energy saving

The solventless laminating machine does not need to be dried, which reduces energy consumption. Moreover, in the late-ripening process, the maturation temperature of the solvent-free composite is substantially the same as the dry composite, so the energy consumption is also relatively close.

3. Safety

Since there is no organic solvent, so no need to adopt explosive and warm measures during production, transportation, storage and use and no need to specifically build a warehouse for solvent storage, more importantly, there is no harm to the health of the operator.

4.High Efficient

The speed of solventless machine adopting solvent-free adhesive is generally 250 ~ 350 m / min, even up to 400 to 500 m / min, while the solvent-based adhesive composite is generally 150 ~ 180 m / min.

5. Low cost

a. The coating amount of solvent-free adhesive is usually from 1.3 to 1.8 g / m2, while dry composite is 2.5-4 g / m2, and therefore, the amount of adhesive consumption can be reduced by about 50% compared to dry composite.

b. Since the solventless composite process does not require a drying process, energy cost is effectively reduced. After calculating, the energy consumption cost of the solventless lamination machine is 1/15 of the cost of dry composite consumption.

c. From the production efficiency, the efficiency of the solvent-free lamination machine is 1.5-2 times higher than that of ordinary dry composite, effectively reduces production costs.

Problems Existed In Solventless Adhesives

1.A great effect on the smoothness of PE film

When the solvent composite ripening temperature is greater than 40 ° C, it has a great effect on solvent-free composite film which has the inner layer of a PE film, and it is easy to appear the phenomenon that friction coefficient increases obviously. This is mainly because the higher the ripening temperature, the more intensely moved the molecular motion of the PE film, which is easy to migrate to the adhesive layer and the reaction is consumed, resulting in the increasing friction coefficient of the composite film.

2.Aluminum plating layer transfer

Aluminum plating film, especially a polyester plating aluminum film, is prone to aluminum transfer during the solvent-free composite, thereby causing insufficient strength of the composite film peeling.

3.Dissolve with ink

During the solventless composite, the phenomenon of adhesive and ink phase dissolution may occur, especially the dye-type ink.

4. Low peel strength of aluminum foil composite

At present, for the solventless composite of the aluminum foil, since the peel strength is not enough, it is still necessary to satisfy the heavy-duty packaging and requirements for cooking resistance.

5. Frequent replacement of solventless adhesive types

With the development of the solventless composite process, many solvent-free adhesive suppliers have introduced general solvent-free adhesives, cooking solvent-free adhesives, aluminum foil special solventless adhesive, low friction coefficient no solvent adhesive, etc. Although the diversification of the product can meet the composite requirements of different materials, the flexible packaging company also has to clean the gluing equipment and solventless machine according to the different composite materials. Not only it wastes time, human resource, financial, but also has low production efficiency.

Development Trend of Solventless Adhesives

1. Functional solventless adhesive

Solventless adhesives should develop to functional products, such as DMF organic solvent mixture with content less than 20%, a product resistant to pesticide corrosion.

2.UV curable solventless adhesive

UV curable solvent-free adhesives have the advantages of fast curing speed, transparent peel strength, non-toxic, non-corrosive, energy-saving and environmentally-friendly, widely used for plastic/plastic, plastic/paper, plastic/metal film, or other materials rapidly solvent-free composite. At present, UV cured solventless adhesive has been developed, but it still needs to increase research and development efforts to launch more mature products to the market.

3.Solventless adhesive used in other industries

The solventless adhesives used for textile, automotive interiors and other industries, as well as paper including kraft paper, cardboard paper, ordinary paper, plastic including various transparent films, aluminum plating films, aluminum foil, should be developed.

Solventless adhesives bring great benefits to environmental protection, health, safety, cost, etc, but still, have some problems that need to be paid attention to. The future development trends of solvent-free adhesives are multi-functional, can be used with various materials in different industries.

The demand for the mask has a rapid growth in recent years, especially after the outbreak of the epidemic and the mask machine becomes important for satisfying the growing need for the mask.

The commonly used accessories of mask machines include magnetic powder brake, air shaft, servo all-in-one web guide system, servo web tension control system, safety chuck, etc.

Magnetic powder brake

The magnetic powder brake is a novel transmission element, adopting powder as the medium, magnetic particle chain formed to transmit torque when energized, which is mainly composed of inner rotor, outer rotor, magnetic coil and magnetic powder. When the coil is not powered, the active rotor rotates. Due to the centrifugal force, the magnetic powder is smashed on the inner wall of the active rotor, and there is no contact between the magnetic powder and the driven rotor. After the DC power is turned on, the electromagnetic field is generated, and the working medium magnetic powder forms a magnetic powder chain with the magnetic line action, which connects the inner rotor and the outer rotor, thereby achieving the purpose of transmitting and brake torque.

Air shaft

The air shaft is based on the principle of air compression. The outer diameter of the shaft is changed and the roll core is privileged, facilitates the transmission of the material on the production line. It is not necessary to unload the whole shaft for unloading materials of the air shaft and the materials can be taken away after direct venting. Since its width is not large, the natural operation is also more convenient. The air shaft is selected for the machine with a lightweight and small width.

All-in-one web guide system

The servo all-in-one web guide system is working, when the web guide sensor transmits the infrared light, ultrasonic, particle beam, or monochromatic light-detecting the web, sending the signal to another sensor. After the sensor finds the web offset, according to the commands set in advance, the controller makes the web guide steering structure swaying and correct the web edge position. The automatic web guide system adopts a photoelectric sensor, ultrasonic sensor, or CCD sensor to detect the edge of the web, and the measured portion deviation signal will be sent into the sensor, and the motor is controlled by the manipulation module.

Web Tension control system

The servo web tension control system is mainly used for automatic folding mask machine. According to the loop tension control, a servo tension control system is divided into open loop and closed loop. Open-loop tension control system is composed of a tension sensor, a tension controller and a tension controller, with no tension value feedback. Closed-loop tension control system is composed of a tension sensor, a tension controller, a magnetic powder brake, a magnetic powder clutch, which has a tension value feedback, according to the feedback tension value, adjusting the control, making the result in a right state. The closed loop control system is more stable. Nowadays, the automatic tension control system is generally adopted, and the generated additional tension will change reversely with the change of unwinding tension, compensating the tension to keep the tension constant.

The web guide system is mainly applied to the lateral deviation control of the coil materials, which can control various reel materials on a production line. The automatic web guide system is simple to operate, easy to install and has fast response speed, strong anti-interference, high-precision web guiding.

The coils are on a long and fast production line, as the speed, tensile, the nonuniform material thickness and all kinds of mechanical damage, resulting in moving and unidirectional deviation, causing the machining operation of the middle section not easy to cooperate, resulting in the loss of many materials and the difficulty of subsequent processing. The automatic web guiding system can solve these problems, which can always keep the edge postilion of the web always be neat and consistent. Web guide control can make steel, corrugated paper, textile, printing, labeling, non-woven fabric processing and other much more industries realize automated control.

A typical automatic web guide system which is a closed-loop system, includes a web guiding controller, a web guide sensor, a web guide framework, and a driver. The sensor detects the difference between the detection value of the edge or the line and the set value, and converts it into a proportional signal through the PLC controller. The driver realizes the web guide. It has three guiding methods, including edge position control, line control and center control.

Technical Parameters Of Automatic Web Guide System

1. Support photoelectric sensor, ultrasonic sensor, CCD sensor.

2. Intelligent detection sensor parameters, no need for calibration sensors in most situations.

3. Automatic stroke measurement, not any mechanical switch needed.

4. Adopts variable PI adjustment algorithm, high precision, fast responding, with smaller error.

5. Super high response speed of 500 microseconds.

6. Analog sensor signal adopts 16-bit AD sampling.

7. Adopts the FIR digital wave filter, with strong anti-interference ability and more stable signals.

v8. DC servo motor pushing the ball screw

9.Support Simplified Chinese, Traditional Chinese, English, three languages.

10. User-friendly operation, fast and easy.

11. Support MODBUS and PLC operation.

High-precision Automatic Web Guide System

The precision of the web guide system is defined as the position accuracy of the web just coming out of the probe. The accuracy of the web guiding system is determined by three factors, including the deviation of the invasive web, the accuracy of the web guiding system itself, the installation accuracy of the web guide machine.

The automatic web guide system is a controller of tracking edge or printed line of the working material to perform high-precision differential and swing, which is composed of large-scale industrial integrated circuits, with strong anti-interference ability, high reliability and long service life. The lateral web offset in the transmission is detected by the photoelectric sensor, and the electrical signal proportional to the offset will be sent to the controller. After power amplification, it is sent to the motor to make it rotate forward, stop or reverse and the motor shaft end is connected with a lead screw. The screw drives the roller to move the rolling roller in the rolling rail to move laterally in the offset direction, thereby reaching the purpose of the automatic web guide. The signal is being firmly measured and the high-precision of the web offset is the premise of automatic web guiding.

Wide Applications Of Automatic Web Guide System

An automatic web guide system can be widely used for various coils such as web films, non-woven fabric, woven fabrics, on a production line.

Applicable industries: printing, packaging, paper, non-woven fabric, lithium battery, rubber tire, metallurgy.

Applicable coils: wrapping materials, such as roll paper, film, metal foil, film, leather, non-woven fabric, woven fabric, etc.

Applicable equipment: print packaging, flexo printing machine, gravure printing machine, label printing machine, slitting machine, coating machine, composite machine, die cutter, blown film machine, etc.

The automatic web guide system is an integrated high-tech product with a wide range of applications, It has the characteristics of fast responding speed, high accuracy, long service life and high stability. It is essential in the coil material production line.