Mesh applications in candle filter and leaf discs

Candle filters

The metal mesh filters are made in both cylindrical and square shapes for standard industrial designs and are custom made to fit in the specific housing. These are made in sintered metal fiber and woven wire mesh.

The designs include heavy duty mesh that offer sufficient strength to withstand high differential pressures about 120 bar in fact higher too if needed. Low carbon steels are widely used to offer supreme corrosion resistance. The thread coatings are offered when essential to prevent the galling of material.

Sufficient care is taken to confirm that the design is free from stagnant flow areas that could slow down the polymer, cross-link and affect. The mesh are offered with internal volume reducers at the closed end to support in it and usually have flow divert characteristics to offer good flow distribution over the mesh when the polymer enters.

In the various designs, the open end can of the candle is made to sink into the tubesheet to confirm extending the filter medium.

For several applications, the Hastelloy mesh pleated candles are used for extended surface area and prolong active life. For few polymers such as polypropylene, it is discovered that the large viscosities refer that there is nominal flow among the pleats and on-stream life is not significantly more than a plain cylindrical candle. The plain candles are preferred in this media.

Uses:

a.       Polyester bottle

b.      Polyester fibre

c.       Cellulose acetate fibre

d.      Nylon fibre

Advantages and characteristics

a.       Sturdiness for cleaning and frequent use

b.      Prolong life

c.       Service at the high temperature media

d.      Supreme carbon resistance

e.      Good filtration area for pleated candle design

The candle mesh filters are customizable to fit any specific housing. They are made in sintered metal fibre and woven wire mesh. The filtration ratings vary from 3 to 100 microns, these are normally delivered with an external guard t secure the media and to permit reverse flow while cleaning. The candle mesh is easily cleanable with advanced technology. The candles are developed with separable hardware fitting and replaceable media to offer lower service costs. They are fit for any industrial designs and can be customized for specific housing.

Leaf discs

Leaf disc and solid plate filters are made for critical hot melt polymer filtration applications to achieve great gel control by offering smooth flow and hence higher gel retention on the filter.

Additionally to offer a great range of filter media, the leaf disc filters provide the great design characteristics ensuring low pressure drops to offer longer stream life. The firm structure permits several cleaning cycles hence decrease overall life costs.

With our extensive experience and great range of filer media, the application and design engineers can custom design adequate filtration products for every product and process, it includes support during design process to attain active performance for the long terms.

We characterize our media and elements service by evaluating them through flow tests, microscopy, chemical test, tensile test, metallography and quantification of polymer contaminant with image analysis. 

Waterjet cutting of superalloys for aerospace applications

The waterjet cutting system implements Dynamic Waterjet Technology. It has active tolerance control to offer unprecedented speed, accuracy and versatility. The patent system develops components with tight tolerances even at the large paces that practically discards taper by using angular compensation. It utilizes an advanced sophisticated motion system that comprises of new mathematical cutting models to monitor the small articulated wrist associated with the cutting head.

It is possible to title the cutting head in any direction by using the wrist to compensate the stream lag and taper occurring with the traditional waterjet cutting systems. For the traditional waterjets, it is essential to decelerate the process to reduce or discard the finished component tolerance errors because of the stream lag and taper. By using waterjet, it is possible to overcome these drawbacks. The position of cutting head can be dynamically controlled by using software that can level the tilt ant rotation required at the various incremental points with a cutting path.

An appropriate cutting speed can be maintained with this software to keep the components taper- free and within tolerance. It is essential to increase the tilt while increasing the cutting pace and in many cases, fast cutting speed can be obtained with the potential to tilt the cutting head. Therefore, Waterjet can develop excellent components at the larger speeds as compared to the traditional waterjet cutting equipments.

Wateret cutting machine capability

a.       Accuracy of +/- 0.0015 inch per 3 feet and speed limit about 0 to 500 ipm

b.      Cutting area about 2m x 2m cutting bed with lengthy pieces having indexing potential

c.       Several tolerance levels and fine cut

d.      Mix and match edge styles on the same part depending on their use

e.      Nominal machining is required on components because of tighter tolerances and outstanding edge quality and highly available due to no need to handle the scrap

f.        Nesting, flattening, kitting, toll cutting and JIT service

g.       Small edge stress and no heat affected region so fit for the elevated temperature and corrosion resistance applications.

Benefits

a.       Cut components 25 to 400% more quickly as compared to the traditional flat stock waterjet cutting devices

b.      Cut various materials such as glass, metal and composites

c.       No additional finishing is needed

d.      Improve cut part tolerances and shape at the significantly high speeds

e.      Virtually prevent aper

f.        Decreases component cost

g.       Cut components by using CAD file and draw directly into FlowMaster

Applications

1.       Aerospace- Titanium bodies and engine materials constructed from titanium, aluminium and heat resistant alloys such as Monel 400 and others.

2.       Automotive- Truck bed liners, interior trim, firewall

3.       Gasket for aircraft, automobile, marine, copper and rubber

4.       Stainless glass, Outdoor stone and flooring, wall inlay, flat glass

5.       Acrylics , plastics, ceramics, stainless steel, Inconel, mild steel, titanium, brass

The waterjet cutting technology has made it easier to cut the corrosion resistant alloys that are usually a hard material that need expensive cutting processes. 

Challenges during Inconel grade machining and work hardening

A winning strategy for effective machining of Inconel, includes wise choices of cutting tools and parameters. A common procedure is 3V precision that s used to machine the Inconel grades economically with cycle times about 24 hours. To efficiently use the Inconel components to continue the procedure and turning a profit, the 3V procedure has become more economical as compare to other machining procedures in cutting this metal. The tools and methods used were a beginning point, however the aim is at meeting the challenges and costs related with this alloy.

The procedure is successful because of the dedication, the procedure continues to draw on the type of promise and engagement as the facility gives the hope to handle the hard metals effectively.

The combination of CNC machines in 3V service includes horizontal and vertical machining units. It is essential to have these units otherwise you do not understand the machining. Efficiency comes through fine tuning process for a machine tool thereafter replicating the success by implementing the same method on the similar machines.

On each processing of Inconel alloy, sufficient materials are set up and retain sufficient metal removal rate with every of these pieces therefore the complete machining cycle time is about 24 hours or low. A time length of 24 hours is trusted to be perfect for machining time since an operator who begins on a cycle lasting this long can determine that he will have this job to unload at the same time on the second day. An operator who invests the day setting up and launching single 24 hour machining after another hence has his next day already planned. They need to visit the machine again and load new components or settle new job.

Attaining cycle time quicker than 24 hours is not essentially an achievement. Neither is receiving a large count of samples in the setup if the density has an effect of increasing cycle time above 24 hours. If these changes can develop a cycle that is out of step in balance with other procedures, and breaking rhythm would result into waiting or hurry, causing error or efforts in vain. Specifically in Inconel, 24 hour standard brings lavishness as it refers that there is no pressure to drive the process to attain the last incremental increase in the machining results.

In machining of Inconel718 grade, the work hardening is more dangerous. The metal can be cut productively, however quick cutting has a way of redeveloping into unbeneficial cutting as the hardened metal begins to rapidly affect the costly tools.

The small speeds and feed rates are utilized initially with the parameters bumped after every successful run as long as quick wear sets in the shop arrives at a process for machining a suitable quantity of these components in a cycle of only within 24 hours.

If the roughening tool is worn then the finisher damages quickly and this wear can eventually affect the success of the unattended cycle or sellablity of the component.