Category : Best Of Welding and Blacksmithing

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This article focuses on Diversified Machine Systems – a 3 and 5 axis CNC Router and Machine Center Manufacturer, located in Colorado Springs, CO. Diversified Machine Systems specializes in the manufacturing of CNC Routing Systems for various industries and use on various materials. DMS Machines are used worldwide, by many different organizations, industries, and governments.

What is a 5-Axis CNC Router?

A 5 axis CNC router is a machine that works on wood and aluminum composite. It can also be used on foams, plastics, polymers and other materials. Basically, this router works by cutting portions of the material to create unique shapes and designs. Unlike manual routers, this makes accurate and efficient carvings and engravings in just a short period of time. If you want to avoid the risk of making mistakes when cutting material, let the router do the job for you.

What’s the Cost?

A 5 axis CNC router can be quite expensive. However, buying this kind of router can be your greatest investment, especially if you want your business to grow. Over time, you’ll be able to make your investment back because it won’t be difficult to increase your productivity. In many ways, a router helps businesses save more money because they don’t have to hire extra labor. With little supervision, the router will cut accurate details over and over again.

It is not easy to operate a 5 axis CNC router. However, if you are thinking of buying this machine, you do not have to be afraid of operating it. A computer that interprets commands to make a design controls the machine. When these commands are logged into the computer, the machine will carve images and engravings as ordered. Most of the time, the router is used to make designs for cabinets, drawers, and doors. In some cases, they can also be used for making interesting designs in plastic, steel, foam, and aluminum.

Manual engraving is a skill that many people have. However, if you have a commercial business that requires fast-paced production, manual engraving may not be enough. To support increasing demand from clients, you have to use a 5 axis router. This will not only make accurate carvings, but it will also help you keep up with orders. This machine carves quickly and accurately. It can also make 3D engravings that many people love.

Common 5-Axis CNC Router Features

Here are some of the Features and common values available from a 5-Axis CNC Router:

  • High Precision Cycloidal Gearsets on Rotary Axes
  • Heavy Duty Tube Frame Construction
  • Spinning Ballnut/Fixed Screw-on X & Y Axes for Increased Rigidity
  • 36″ Z Axis
  • Fagor 8055C Controller
  • 11″ Color LCD Monitor
  • 5 Meg Part Program Storage
  • DNC
  • Part Program Graphics
  • 1.75′ Thick Machined Aluminum Table Tops
  • 35 mm Star Linear Profiled Ways on all Axes
  • Safety Guarding
  • Closed-Loop Brushless AC Servo Motors
  • Inverted Z-Axis Counter Balance Cylinder

Other Additional Features Are:

  • Automatic Tool Changer
  • 10 HP ISO 30 Spindle
  • 15 HP HSK 63F Spindle
  • 48″ Z Axis
  • Automatic Lubrication to Ballnuts and Way Bearings
  • Automatic Vacuum Valve Control
  • Remote Operators Station
  • High Precision Fixture Table
  • Automatic Tool Height Sensor
  • Remote Teach Pendant Programmer
  • 5 Axis Tool Length Compensation (TCP)
  • 1 GB Compact Flash Card With TCP/IP Network Connection
  • CPU Turbo

CNC milling is a very precise machining system that is automated and follows data programmed to specification. Any trained technician can use any CNC milling machine and accomplish the machined part requirement per the program this is in the CNC milling machine. This versatility can be utilized anywhere in the world with a proper environment for the CNC milling machine can perform their programmed operations to accomplish the tasks programmed. CNC milling is the worldwide accepted way of producing precision machined parts per blueprint engineered drawings.

CNC milling machines are durable and the CNC milling cams that are made per programming specification can produce machined parts by the hundreds with reliability and compliance to specific quality control tolerances that are programmed to the CNC milling machines. The CNC technicians can operate the normal CNC machines operating process, which they are accustomed to running, and the CNC milling machines. The CNC milling machines will follow the CNC cams that have been installed during the setup of the CNC milling machine.

Where I Can Find Precise CNC Machines

CNC milling machines can be found all over the industrialized world. These CNC milling machines are self-contained and can be shipped all over the world. The machined parts made by these CNC milling machines can be shipped anywhere the customer needs them. Corporations that use these CNC milling machines very much fulfill the marketplace need for CNC milling machined parts, for products and services for worldwide corporate marketplace demand. CNC machines are Cam operated and computer-operated systems this can be a valuable resource for all diversified companies worldwide.

How Precise Can They Be

CNC milling can be programmed for general and specific tolerances that fulfill the different requirements of the industries of the world. The tolerances can be from one-eighth of an inch to one-thousandth of an inch. These CNC milling machines can make machined parts beyond the imagination; this versatility can be used everywhere and for everything. This concept helps the CNC milling companies adapt to any marketing for diversified industries in their local community and to the neighboring countries and contribute to the worldwide demand for CNC milling machined parts. Industrialized areas of the world are wearing out parts and the need for good quality CNC milling machined parts are forever in demand. This is an ongoing process throughout the world.

Modernization of Machining

I cannot imagine the world without the CNC milling machines, to crank out production of machined parts to comply with the ever-pressing need for precision machined parts for any machine, auto, airplane, industrialized equipment, and the list goes on and on. The CNC milling machine has earned its place as an accepted way of accomplishing the nearly impossible task of supplying precise and consistent supply to corporations all over the industrialized centers of the world. CNC milling is an automated process that generates a machined part to meet the specific needs of the diverse machines of the world.

CNC milling has been an accepted method of machining for several years and has evolved with modern technology. This modernization of machining has made CNC milling a complete success and has kept up with the industrialized world of today.

The manufacturing of industrial parts has evolved greatly over the last century. There was a time when all items were at least partially created by hand regardless of how many need to be manufactured. Assembly lines, new metals and materials, and new forms of power eventually lead to semi-automated forms of production. Unfortunately, this type of production was very expensive and very inflexible. The later development of a numerical control machine gave manufacturers the ability to use a single machine repeatedly with the same settings to slowly create perfectly identical pieces out of metal or wood. These original machines required numerous manual adjustments and sometimes multiple operators just to generate a single part.

How CNC Changed the Game

The development of computers and other new technologies lead to the invention of the the computer numerical control (CNC) machine. This was similar to the original numerical control machines except that a computer allowed the operator to enter in a sequence of commands that would be executed with unmatched precision. A single CNC machine gives companies the ability to develop a program that can be executed in exactly the same fashion automatically at any time. The ability to develop a program ahead of time with other pieces of software allowed for rapid prototyping of new products and a reduction in errors and wasted materials.

One of the largest changes that a CNC machine brings to a business is the ability to reduce the amount of staff required for creating parts. A single skilled operator can program and maintain one or more units. This can result in a single worker overseeing an array of machines that are constantly producing parts. A CNC machine is also much more dynamic than previous types of manufacturing tools and can be adjusted to cut a variety of materials or to make a wide range of different patterns, holes, or designs.

Current Trend on CNC

Modern companies are able to use a CNC machine to create highly detailed parts that are used in many different industries. Everything from engine parts to surgical tools can be created with the right CNC program and materials. New technologies have allowed machines to continue to evolve. More efficient cutting techniques, more advanced computer control systems, and better machine designs take the process of generating parts automatically to a new level. The newest machines are able to run for days at a time without maintenance and are capable of delicate work that was once only achievable by hand.

The basic question that I encounter is commonly by a person who’s looking for a way to learn how to MIG weld. Whether they’re unaccustomed to MIG welding or are just looking to learn some new MIG welding techniques, there is never an end to these questions.

I don’t mind though. Do you know why? The reason is that MIG welding embodies among the most valuable and coveted welding techniques in the industry. Once you figure out how to MIG weld, you are well on your way to becoming a very proficient welder. I will begin these articles with a bit of background info on MIG welding and then will discuss a few basic MIG welding techniques.

MIG Basics

Properly called metal inert gas welding, MIG welding is a type of gas metal arc welding (referred to as GMAW). MIG welding applies an electric flow to provide an electrical arc between a consumable wire electrode in the welding gun and the workpieces. Shielding gas is likewise employed in order to protect the weld from atmospheric gases that may interfere with its quality.

How long has MIG welding been around? It was produced in the 1940s as a way to easily and with efficiency produce equipment and arms during World War 2. It was (and still is) preferred in welding shops because of the ability to learn how to MIG weld quickly, and also the low cost and time tied in with it. Somebody with an introductory understanding of welding should be able to learn how to MIG weld and run good beads with just a couple of hours of practice. MIG welding is also quite popular because of the low investment cost – a new, quality machine for your garage or workshop prices approximately $500. As good as that price is, you are still able to find new ones cheaper, but you definitely get what you pay for there.

What Welding Techniques Exist

Now that you have a basic understanding of MIG welding, I believe it’s time to go on to some MIG welding techniques. As important as background knowledge is once you’re discovering how to MIG weld, it needs to be coupled with practice. These MIG welding techniques will get you on your way to creating strong, visually appealing welds.

For someone first ascertaining how to MIG weld, a zig weaving design is probably the best starting point of the MIG welding techniques. The zigzag pattern can either be done as push (welding away from you), or pull (welding toward you), and is executed precisely as it sounds. Your goal is to make even, steady zigzags across the joint of the two workpieces. This is an absolutely easy design to learn and get quite effective at very quickly. Using this MIG welding technique, you would generally pause at the end of each zigzag (on the sides of the joint) for a brief second in order to help spread out the weld. The key to these is to make certain that you get a steady rhythm going when working with equally thick workpieces. Once you have become familiar with this welding design, you are ready to move on to how to MIG weld using a slightly more advanced MIG welding technique.

The next technique is a circular design. For someone who is learning how to MIG weld, this technique is still relatively basic. It does take a little bit more practice and concentration than the zigzag pattern, but it is still a very achievable figure. For this process, you’ll weld in slow, circular motions. Depending on the workpieces, and the weld you’d like to create, you’ll be able to either use small, precise circles or a larger, more encompassing pattern. After a little practice with these MIG welding techniques, you are know how to MIG weld nearly any basic project that you wish to do.

Final Thoughts

While no single article can teach you all of the information you need to know about how to MIG weld, this should have been a good basis for your entry into the world of MIG Welding. Keep practicing and you will find success in your efforts.

The letters of CNC mean Computer Numerical Control and this process of controlling the machines through the computer has been around since the 1970s. There are very few people who have heard this term but this concept has affected every form of the process of manufacturing that you may know for a long period of time. There are different forms of manufacturing that are using this concept of working with the control of the programs but still there is not much knowledge among people for this. The CNC Machining is therefore becoming more and more important as the need for such a system is growing. Here are the ways CNC improves efficiency.

CNC Control on Conventional Machines

The conventional machines used to do work that was not very fast and so the concept of the CNC Machining came up for faster production and you will find the operator that used to operate the conventional machines are not much required for the CNC period. The machines work on their own and they are guided by the program that the computers control them with to bring much more perfection in work and faster timing. The workpiece loading in the machines is automated. The CNC operators often are few in numbers and they do other things regarding the CNC machines but need to be there to supervise the whole thing. The machines keep running till the whole work is completed.

Motion Control and Production

The CNC machines have got this feature of motion control. The two axes of different directions of motions are measured and these axes of motions are sometimes linear and sometimes rotary or work along a circular line. The different types of such machines bring about changes in the industry as the production is raised and the requirement is filled fast without any deficiency. The machine’s efficiency is counted on how many axes it has got and it gets complex on the increase of its number of axes. These axes cause the motion that they need and there are also different types of drilling and turning off the machines that can be achieved by the machines.

Cutting Tools and the Precision of Axes

When the CNC Milling machines are used for the specific work that they are required for, they also give a better performance and brings in the foreground the usage of horizontal and vertical machines that are designed for special work. The positioning of all cutting tools must be proper though the operation may be horizontal or vertical. The larger machines are for working with larger components and the smaller ones work with smaller ones. These machines are also used to work with the a bigger range of components and there are factories that have CNC Milling machines that are used with 4 axis or 5 axis machine centers.

Advanced Software

There are machines that are controlled by software and the updates of the software are important for the machines to work efficiently. The updates or the improved versions of the software give the machine more precision and better performance. The machine operator should be proficient with the G-code programming and the different other conversational programming. The CNC Mill are therefore the most efficient and commonly used machines that are controlled by the software that are for advanced control for better production.

There is a warm, hospitable beauty that is unique to a country-style home. More than the inviting colors, fresh look, and happy atmosphere, there is energetic tranquility that courses through the home and welcomes anyone that steps inside. The ability to decorate is in itself a beautiful thing because it allows you to communicate yourself through the venue of your home. When you are decorating a country home, one of the tools that can help you communicate clearly is the use of wrought iron in your decorating scheme.

Decoration Ideas

There are many options for using wrought iron throughout the living areas of your house; one of these options is the use of wall hangings. Several different types of wall hangings can be considered, ranging from wall sconces that hold candles, to the decorative designs of wrought iron grilles and medallions that serve as three-dimensional pictures. You can also find wrought iron clocks and even shelving that is perfect for holding lightweight books, candles, or figurines. Hanging planters are great for adding both class and color to your décor, and coat and key holders are a practical addition as well as an attractive one. Little artistic iron keys are easy to find and look great hanging on iron key holders when suspended by a satin ribbon looped through the handle.

Curtain rods are a great subtle way to add wrought iron into your décor and can be used in any room. Another subtle accent can be the handles on your furniture-changing them to wrought iron as well will add a tone of delicate consistency throughout your home. If you have blankets you would like to display in a bedroom or living area, look for a wrought iron towel holder that is free standing. These have both utilitarian and aesthetic benefits. You might also look for basket tree, which looks like an actual iron tree with arms for hanging small, decorative baskets you wish to display. If you have a fireplace, be sure to choose a screen that incorporates wrought iron in its design, and try to find a matching fire tool set and log holder as well.

Small iron accessories can also be effective in country home décor. Delicate candle holders and platforms are classic and easy to find, and if you have a large picture to display, look for a wrought iron picture stand to hold it up. Lanterns, clocks, free standing crosses, and other figurines shaped from iron are easy to find in almost any decorating store, and look great on a shelf or table.

Accessories such as a hanging pot rack, chandelier, and wine rack can go a long way in carrying the country theme into the kitchen. Smaller pieces such as napkin and paper towel holders, cookbook stands, and soup spoon holders can be tied in as well. Wrought iron spice racks look great standing on the counter, and plate racks hung on the wall add a nice touch as well.

Wrought iron bathroom accessories such as a towel rack, toilet paper holder, and shower rod can tie in the country theme to your lavatory, and a simple accent such as a candle holder can contribute as well. If you have a garden or patio, consider adding a wrought iron table and chair set, along with a garden trellis or decorative fence that you can use to support a flowering vine. Window planters and hanging baskets are other great iron pieces that will help carry your theme outdoors.

Final Thoughts

Decorating your house with wrought iron is simple to do, as you have many options available to you, and they are all easy to find. Discount stores like WalMart and Target have plenty of wrought iron accessories, and stores like Kirklands and Garden Ridge will have a wide variety as well. Wrought iron is a great addition to a country home, and very effective in tying your stylistic theme effortlessly from room to room. The result will be a warm, hospitable house that you can’t help but love coming home to!

Anyone who has experience with fireplaces knows that burning wood directly on the floor of the fireplace doesn’t really work. A good fire needs good air circulation, so it’s almost imperative that the logs are lifted off the ground a few inches. There are many types of fireplace accessories out there that will solve this problem, although andirons are usually the best and most attractive option.

Using Wrought Iron Andirons

Many people use a traditional wrought iron log rack in their fireplace. They work well, they’re sturdy, and they can be nice to look at. Wrought iron andirons have one major advantage over fireplace racks, however. Since andirons are not attached to each other, you can move them closer or further apart from each other depending on the size of your logs.

Andirons have some major design advantages as well. Since they’re always made with tall front support beams, they can really become the focal point of your room. People’s eyes are always naturally attracted to the fireplace, and having beautiful wrought iron andirons framing your hearth can really look impressive.

There is one final benefit of using wrought iron andirons that many people never consider. Iron has the ability to absorb and retain quite a lot of heat. Even when your fire has gone out, your andirons will remain hot and will continue to heat the room. In this sense, they’re also great for energy conservation and for keeping your room warm for longer periods of time.

I have an ’89 F-250 with an externally regulated alternator. I researched weldernator conversions and I wanted to get some first-hand experience before I altered my charging system. I collected some parts and built an alternator welder powered by a lawnmower (see my blog for details). It worked well enough for me to justify converting my F-250.

Modification Process

I picked up a large project box from Radio Shack, a double-throw switch, an automotive battery disconnect switch, a choke/throttle cable, and a 200 volt DC gauge from eBay. I had some 6 gauge wire, jumper cables, 110v outlet, and a 60 amp winch disconnect plug laying around the garage. I made my welding cables from the 6 gauge wire. I used the jumper cable clamps for the ground and electrode clamps. I used some scrap 5/16″ copper tubing to make some butt connectors to attach the wire to the winch plug.

I fitted the volt gauge, outlet, and double-throw (DT) switch into the project box. I used the studs on the volt gauge as the junction for all of the wires. The battery disconnect switch breaks the connection between the alternator and the battery to prevent overcharging. The center post of the DT switch is wired to the “field” post on the alternator. One of the remaining switch posts is connected to 12v+ and the other post is connected to the “field” wire from the voltage regulator. The switch allows you to bypass the voltage regulator and full-field the alternator by sending 12 volts to the field post on the alternator.

Most guys use welding disconnects to attach the wire to the control box, but I had the winch plug so I used it. I was going to use welding ground clamps and electrode holders, but I wanted to be able to reverse the polarity if needed. The welding plug prevents me from plugging the wires in backward so I used the jumper cable claps as the ground and electrode holder. They can easily be switched from ground to electrode and the price was right (free).

The 110v outlet is wired to the positive and negative posts on the back of the volt gauge. It can be used to power a 110v AC tool that has brushes (saws all, grinder, drill, etc). It can also power anything that uses a transformer like a cell phone charger and incandescent light bulbs. The choke/throttle cable is needed to bump up the engine rpm and generate the voltage needed for welding or operating the power tools. I swapped my large alternator pulley for the smallest one I could find. It spins the alternator faster and lets me keep the engine rpm’s lower while welding. I upgraded the positive wire from the alternator to a 6 gauge wire. It runs to the positive post on the volt gauge where it connects to the positive side of the winch plug, 110v outlet, and the battery disconnect switch. The battery disconnect switch is connected to the positive side of the battery. The negative side of the volt gauge is connected to the alternator with a 6 gauge wire. It’s also connected to the negative side of the 110v outlet and the negative side of the winch plug.

How to Use it

The first step to using the welder is to turn off the battery disconnect switch separating the battery from the alternator. Plug in your welding leads and flip the DT switch from charging to welding. Pull the choke cable until the engine reaches the desired rpm’s. My large body Ford alternator generates about 70 volts at 2,000 RPMs. I get good penetration in 1/4″ steel at that setting with a 3/32″ 7018 rod. I was worried about overloading the 6 gauge wire and the winch plug, but they were not hot after burning through 3 rods. The alternator was warm but did not seem to be too hot. Make sure to switch back to charging mode before you reconnect the battery to the alternator.

If you have an alternator with an internal voltage regulator or do not want to modify your charging system you can add a bracket for a Ford alternator to your engine. You can search the junkyard for a bracket to modify or make one from scratch. If you do not have room under the hood you can simply remove the second alternator when you are done welding and store it inside the vehicle.

For cabinetry with a more hand-made look, many people choose to use wrought iron hardware and accessories. While wrought iron may not be the most durable of materials, many people are drawn to the rustic look and feel of it. Wrought iron provides a medium for many artists, so if you are looking for handmade, one of a kind items, wrought iron is a good place to start.

Because wrought iron has the propensity to rust over time, make sure to choose a durable lacquer or finish when selecting hardware made of this material. Some may choose to pursue the darker traditional look, letting the true color of the iron shine through with the aid of a protective coating. Others may opt for a color lacquer, with will also protect the metal against damaging moisture.

What is so Special With Wrought Iron

Decorative hinges are easy find when seeking out this particular material, largely due to the history of the material itself. There are actually three types metal that are classified as wrought iron, yet only two of these materials are actually true iron. Charcoal iron was the original version of wrought iron, and was the metal of choice for blacksmiths before the eighteenth century.

During the nineteenth century, technology was made to improve the strength and malleability of iron, whereby puddle iron was created. When you come across genuine antique wrought iron hardware, it is most likely made of puddle iron. Because the consistency of this iron was easier to control, more decorative accents could be included within the hinge and handle design.

Finally, most new wrought iron hardware is actually made of mild steel, as it has recently replaced puddle iron in the hardware industry. While this material does tend to be stronger than traditional wrought iron, it also tends to corrode and has a shorter life span. However, despite this shortfall, mild steel’s strength and consistency has given wrought iron hardware a broader range of options in style and design.

Blacksmithing is a 3,500-year-old profession. Blacksmiths were working on metal projects as far back as the Bronze Age. In the past, blacksmiths had to rely on manpower to get the job done, but nowadays, industrial blacksmithing power hammers are helping to make the work much more efficient.

Significance

The Blacksmithing profession has come a long way from manual labor to a more automated process. Blacksmiths no longer have to toil long hours over the same slab of metal; industrial blacksmithing power hammers now make the job easier. Additionally, metalworking products are of superior quality compared to what was produced in the past.

History

Blacksmiths have been around since the beginning of modern civilization. In fact, the blacksmith profession can be traced back to the Bronze Age (about 3000-1500 BC). Blacksmiths were the toolmakers and manufacturers of their time. They were responsible for constructing tools, weapons, and machinery out of bronze, steel, and iron. There were also decorative and architectural blacksmiths who made gates, fences, and artistic pieces.

When completing these projects in the past, Blacksmiths had to rely on pure manpower; they had to hammer steel and iron by hand. This is why many blacksmiths had to be strong and able-bodied.

Luckily, today there are industrial blacksmithing power hammers available for metalworking projects.

Benefits

Compared to elbow grease, industrial blacksmithing power hammers have a lot to offer modern blacksmiths in the way of convenience and ease of use.

There are two main types of blacksmith power hammers: mechanical hammers and air hammers. Mechanical hammers use a crankshaft to power the machine, while air hammers are powered by air cylinders. These motorized hammers can deliver up to 500 pounds of force. The additional power allows modern blacksmiths to bend metal more accurately. You can easily adjust and move the metal you are working on, which helps shape the entire metal piece with greater precision. For example, if you need the metal to bend at a sharper angle in a certain place, you can set your blacksmithing hammer accordingly. So all in all, you will get a better quality product when you use a power hammer.

Challenges

There are a few downsides to industrial blacksmithing power hammers. For one, these hammers are much more complicated to use as compared to a regular hammer. With the basic hammers Blacksmiths previously used, all that was required was a good grip on the handle and some manpower.

But you have to be trained to use an industrial blacksmithing power hammer because there are many settings to navigate. Also, a power hammer is a dangerous tool; you have to be sure that you are taking every safety precaution when using one of these machines.

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