The Year of Engineering is a government campaign that has been established to celebrate the wonder of the field and is aiming to shake up people’s perception of engineering. In 2018, this campaign plans to inspire the next generation of inventors, innovators and problem-solvers by demonstrating what engineers actually do.
Performing maintenance on a hydraulic system, the correct way, is by utilising the maintenance best practices.
Many businesses opt to spend a large sum of money to train their maintenance staff to troubleshoot a hydraulic system.
However, by focusing on the prevention of system failure, it would lessen the amount of time and money spent on troubleshooting a hydraulic system.
It is often that companies will accept hydraulic system failure as a thing that happens, instead of the opposite – it would be more beneficial to invest time and money in the elimination of a failure rather than the preparation for failure.
The forefront runner of component and system failure is the lack of maintenance of the hydraulic system, although a majority of maintenance staff won’t know or understand, the proper maintenance techniques of a hydraulic system.
To perform the correct maintenance on a hydraulic system, two areas require concern: the first is preventive maintenance – the key to the success of any maintenance program, in hydraulics or any equipment where reliability is needed. The second is corrective maintenance – if not performed to standard, this can cause additional hydraulic component failure.
The basic foundation to perform proper maintenance on a hydraulic system has two areas of concern. The first area is Preventive Maintenance which is key to the success of any maintenance program whether in hydraulics or any equipment which we need reliability. The second area is corrective maintenance, which in many cases can cause additional hydraulic component failure when it is not performed to standard.
This is a simple and basic form of maintenance that has the ability to eradicate a majority of hydraulic component failure, if followed in the correct way.
– Identify system operating system’s condition: does the system operate 24 hours a day? 7 days a week? Does the system operate at maximum flow and pressure 70% or better during operation? Is the system located in an unclean or humid environment?
– What requirements does the Equipment Manufacturer state for Preventive Maintenance on the hydraulic system?
– What requirements and operating parameters does the component manufacturer state concerning the hydraulic fluid ISO particulate?
– What requirements and operating parameters does the filter company state concerning their filters ability to meet this requirement?
– What equipment history is available to verify the above procedures for the hydraulic system?
Divide the necessary hydraulic skill into two groups: the hydraulic troubleshooter and the general hydraulic maintenance staff – those that provide the preventive maintenance expertise.
Hydraulic troubleshooter knowledge:
– Mechanical Principles / force, work, rate, simple machines
– Math / basic math, complex math equations
– Hydraulic Components / application and function of all hydraulic system components
– Hydraulic Schematic Symbols / understanding all symbols and their relationship to a hydraulic system
– Calculate flow, pressure, and speed
– Calculate the system filtration necessary to achieve the system’s proper ISO particulate code
Hydraulic troubleshooter skills:
– Trace a hydraulic circuit to 100% proficiency
– Set the pressure on a pressure compensated pump
– Tune the voltage on an amplifier card
– Null a servo valve
– Troubleshoot a hydraulic system and utilize “Root Cause Failure Analysis”
– Replace any system component to manufacturer’s specification
– Develop a PM Program for a hydraulic system
– Flush a hydraulic system after a major component failure
General hydraulic knowledge:
• Filters / function, application, installation techniques
• Reservoirs / function, application
• Basic hydraulic system operation
• Cleaning of hydraulic systems
• Hydraulic lubrication principles
• Proper PM techniques for hydraulics
General hydraulic skills:
– Change a hydraulic filter and other system components
– Clean a hydraulic reservoir
– Perform PM on a hydraulic system
– Change a strainer on a hydraulic pump
– Add filtered fluid to a hydraulic system
– Identify potential problems on a hydraulic system
– Change a hydraulic hose, fitting or tubing
For more information about our Hydraulic Cylinders and our services, please visit our website!
The versatility of stainless steel fabricating techniques is such, that there is a wide range of it.
Although it has quite high strength and work hardening rates, stainless steel is malleable enough to be bent, folded, machined, welded, deep drawn, or spun.
Work hardening with stainless steel
Work hardening is a term used for the process of strengthening material through deforming it.
When working with stainless steel, depending on the grade of alloy, the work will harden pretty fast.
It’s quite helpful to match the steel grade with a work hardening treatment that is most suitable for the steel.
Tips on how to machine stainless steel
Machining stainless steel can be a tricky process because of the possibility of chipping the steel.
There are ways of preventing chipping happening when machining stainless steel:
– Apply coolants or lubricants to the equipment
– Use large tools to help dissipate heat
– Maintain light cuts and constant feeds
– Use chip breakers to deflect debris
– Select a machine tool that reduces vibration
– Keep the cutting edge sharp, at all times
Welding stainless steel
A majority of stainless steel products can be welded, but the efficiency does depend on the grade:
Austenitic – Most of the austenitic grades are suitable for welding, however this particular group can suffer from inter-granular corrosion on its thicker products.
When welding thick materials for projects, something to consider would be using low carbon content grades.
Martensitic – These types of grades are good options for welding, though they’re prone to cracking.
To reduce the possibility of fractures occurring, heat the material prior to welding, and afterwards.
Ferritic stainless steel – It isn’t really a suitable grade for welding but some may be appropriate for certain projects.
Issues presented may be sensitisation, low ductility and high grain growth can be overcome with the help of austenitic stainless steel fillers, or by heating the welded material, after it’s been welded.
Duplex – Low thermal expansion is more suitable for this grade.
For more information on steel fabrication, please visit our website!
You may have heard of steel fabrication, but do you know how it works?
Steel is an alloy, made from a combination of iron and a number of other metals including carbon, silicon, phosphorus and sulphur. There are varied amounts of these metals present in steel, but it’s commonly found that levels of carbon should be below two percent, with other metals in steel being below one percent. Steel can be cut, shaped and moulded into a range of products; which can all vary from household appliances to vehicle components.
The process in which steel is bent and shaped is widely known as steel fabrication. The birth of steel fabrication came in 1856, when Henry Bessemer, a British inventor, smelted steel. As time has gone on, steel fabrication has evolved into an incredibly advanced process, one that’s way more effective in the modern environment. To this day though, the skill and technique required in order to smelt steel rests at an incredibly high level.
The process behind steel fabrication
In steel fabrication, there are two existing methods that are used universally. The first method of steel fabrication is known as the ‘integration’ method, where the raw material found in steel are heated until they melt, and then being mixed together. Steel that is fabricated today is made using this method.
The second and final method is a process that’s used with recycled steel. This process is known as the Electric Arc Furnace Method, which is the quicker method out of the two. Recycled steel is placed into a furnace, then being melted and set, cut and bent into its final product.
When taken into account, both methods of steel fabrication require a huge amount of skill and precision in order to be done correctly. As of this blog being written, there are as many as three thousands types of steel known to man, with each type holding its own chemical properties, as well as its physical properties.
With the experience held at Taylor Engineering, we know everything there is to know about steel fabrication. Don’t believe us? You can either call us on 0121 326 9035 and even email us regarding any questions you may have on email@example.com! Our employees are more than happy to help with any needs you may have, providing the answers to questions you may hold! You can see a list of our services and products here!
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Steel fabrication is used in a number of objects, but what exactly is it?
Steel fabrication is a term that’s used to describe the process of the cutting, forming and the overall shaping of steel alloy, a process that’s done to create a product. Unlike welding, where items are either strengthened or repaired, steel fabrication takes numerous amounts of mental, attaching them together to form a predefined shape and size. A skilled technician is needed in order to carry out such a process, using their in depth experience and knowledge to create marketable objects from raw components. There’s usually very little room for any form of error in the process, as it’s one of the most common forms of item production. Industrial giants use steel fabrication as a way of creating all forms of products, from vehicular items to household appliances.
A steel fabrication machinist is employed to shape raw materials into various forms, depending on which product they are trying to produce. The process is usually completed using either heat, pressure or electricity, helping mould and form various shapes. Though most of this work is achieved through using heat as a way of steel fabrication, a small part of the process can occur through harnessing various electrical forms. Both processes share the function of firstly melting down any metals through extensively high temperatures, then using various other forms of treatment to form the various shapes.
Once the steel has gone through the processing stage, the next step in the process it to determine which specific shape the steel is going to be formed into. There are two specific factors that will have effect on the outcome, most commonly the software package that’s used and what equipment is at hand to those in the machine shop. Various equipment does different things, so a machinist with a wider range of tools will have a higher ability to form a shape. Cutting edge technology is often adapted by most steel fabrication companies as a way to offer the best service in the steel fabrication process. The cutting edge technology allows for the maintainence of high profiency, allowing for high quality items to be produced. This will also allow superior accuracy on the finished product.
The final outcome of the steel fabrication process is visible in the impeccable steel frames that harness modern businesses, as well as a high number of both industrial and commercial appliances taking from the works. The steel fabrication pieces are often used in other products, such as pipe supports and ladders, making it a mandatory process for modern items.
Hydraulic Cylinders, used to help with the lifting, pushing, dumping, hauling, crushing, drilling and digging they’re maybe one of the most important mechanical inventions which has fitted around us.
When manufacturing a hydraulic cylinder the process is now a lot more streamline with much tighter tolerances, the sheer amazing amount of force a hydraulic cylinder can produce is based upon a mechanical principle of pressure. The way the pressure is worked out is by this formula – Area X Psi = Force.
Hydraulic Cylinder – More Explanation
The hydraulic cylinder has main parts which make up the mechanism which includes the Piston, a piston seals, rod and the gland and butt.
The Rod which the piston is attached to is attached to a large nut at one end, as one of the hardest working component it’s extremely strong to resist bending and is also made out of steel. The piston inside the hydraulic cylinder is used to help build pressure and is done by using a piston seals to keep pressure from bypassing each other.
The Gland is also known as the head of the cylinder and helpes the rod retract and extend, this part contains wiper and rod seals to help keep contamination out of the hydraulic cylinder.
So there you have it, this simple but yet extremely useful mechanism is built using simple parts with very good accuracy in determining the amount of pressure each hydraulic cylinder can produce.