Processing of ZEDEX® materials does not require special machines or equipment and can be carried out on metal-cutting or woodworking equipment, lathes, milling, drilling, planer machines. Manual processing is also possible: by using files, scraping (shaving), grinding, ribbing.
For the production of polymer parts different ways of processing are used in our Dzerzhinsky manufacture:
When processing an antifrictionZEDEX® plastic by milling, surface quality depends on a cutting edge of the cutter, conveying and cutting geometry. To avoid overheating of a blank, the width of the chip should be highest possible that is achieved by great depth and speed cutting of milling with an increase in supply. For example, the gears of high quality are made by the method of milling, which cannot be achieved by casting.
A high feed is required during grinding of the material. For optimal quality it is better to work with a wide cutter, in so doing the desired contour and surface quality should be achieved at one time. Internal processing is done with the standard tools with the regular chip removal. A drill with a small angle of helix is recommended to be used while grinding inside. When cutting thin-walled parts, sharpened tools should be used. When a large length of a blank the use of steady rests is also recommended.
For manual turning it is good to use a largely cut file or a wood rasp, especially with a double cut. When using tools with a double cut chips break at the crossing points, and the surface turns cleaner. To achieve high smoothness of the surface, refinement with a razor-sharp planing (planer) knife is produced. One can process the edges of a blank with its help as well. For smoothing down of welding seams scrapers (no less than 2 millimeters radius) are used to make seams rounded, that will allow to avoid unnecessary stress concentrations.
Almost all ZEDEX materials can be smoothed and grinded, but it is necessary to avoid overheating of the treated surface. Grinding belts or large grain wheels may be used for grinding. To avoid the block of pores with small particles of material during the process, it is recommended to use cooling liquid.
Holes for metric threads with a diameter up to 8 mm should be about 0.1 mm larger than the holes for the thread in the metal and ones with a diameter from 10 mm – 0.2 mm, respectively. Threading is produced by the tools customary for metal-processing. For strengthening of the nut threading a metal insert may be used.
When cutting with a bandsaw cutting speed should be 8-25 m/s, at lower speeds the cut turns out not too clean. Cutting speed should be high enough for a clean cut. Blades and wheels must be with the teeth of carbide steel and have a sufficiently large separation of the teeth (recommended tooth pitch - 4 to 6 mm). To avoid cracks during sawing of some ZEDEX, polymers, blanks should be heated before processing.
Practically any appropriate equipment used in wood- and metalworking production answers purposes of planning.
For drilling of ZEDEX materials HSS-drills for metalworking are used. Deep drilling is recommended after pre-heating of blanks only and with regular cooling and chip removal by air. Drilling of holes with high dimensional accuracy is best carried out in two stages: – first, preliminary and then, after cooling, – hole drilling of a desired size.
More detailed recommendations for machining of wear-resistant antifriction ZEDEX materials can be viewed by clicking on the links:
Download General guidelines for ZEDEX machining
Download General guidelines for the manufacture of ZEDEX parts
Other manufacturing methods
For ZX-100K material any mechanical processing is possible depending on the technological capabilities and purposes.
Preparing for bonding
Preparation of plates (sheets) for bonding is performed using a sander or sandpaper with a large grain. One side of the surface is roughed in one direction (machine or sander with large grain sandpaper in one direction).
Bonding of ZX-100K is processed with one- (at operating temperature from -30ºС to +80ºС) and two-component adhesive (at the operating temperature from +10 to +60°С) depending on the application temperature.
In the first case, a layer of adhesive is put on the plates prepared for bonding by roughening of the bonding surface at the rate of 0.3 kg to 0.5m². Hardening time is 14 days.
In the second case, the adhesive compound (adhesive in combination with hardener) is also applied to the roughed surface. A great set is designed for 6m² of bonded surface, a small one is for 3 m², , respectively, hardening time – is 24 hours at a temperature of +23ºC. After applying of the composition (two-component adhesive) joints are treated with a universal sealant composition (preferably automotive) which is rubbed into the adhesive joints and kept for days, after which the remains are scraped off.
The material is suitable for producing of both angle and straight riffles. Herewith both single and double rollers may be used.
If necessary, inscriptions and other elements can be engraved on the surface of the material both by cutting, getting depressed contours, and by removing the top layer, so that the elements turn out convex. As well engraving practically level with the surface is possible.
Profile excavation and contour milling
The material, which dimensions do not exceed the maximum allowed for this type of processing, slotting of defined profile is possible, as well as contour milling of various configurations based on specified drawings or profiling of various degrees of complexity.