Thermal Spray Process Showcase: Undercut Pre-Machining
In manufacturing terms, the undercut is a special type of recessed surface. At A&A Coatings, we use the term “undercutting” to indicate the amount that a component is turned to provide sufficient space for the sprayed coating. When we say turning, we refer to a material removal process (note that turning is a form of machining).
We utilize this process to cut away unwanted material so that rotational (typically axi-symmetric) parts can be created. In addition, equipment such as cutting tools, fixtures, and turning machines allow us to create anything from contoured surfaces, diameter steps, tapers, threads, grooves to holes on the workpiece or parts.
Before parts can be coated again, we will perform undercut pre-machining to remove any visible damage: corrosion, erosion, wear, and etc. Doing this is required for most repair processes and we want the undercut to be below any of those damages. In addition, we can ensure that the finish thickness of coating is equal to the depth of the undercut and vice versa.
The Capabilities of Our Undercut Pre-Machining Process at A&A Coatings
Our undercut pre-machining process is compatible with all materials in the industrial machinery industry. Also, with a typical tolerance of ± 0.001 in – considered very good tolerance. Best of all, we only require a short lead time to create cylindrical shapes for both solids and thin-walls. Undercut pre-machining is best utilized for rotational parts of a wide variety of machine components, shafts and engine components.
Equipment Used in the Undercut Pre-Machining Process
In the undercut pre-machining process, we use lathes of varying sizes and designs. This means both vertical and horizontal turning machines are used. That’s why at A&A Coatings, we are able to work with large diameter workpieces. For greater turning accuracy, we also utilize computer controlled units; specific commands are pre-programmed in our computer numerical control (CNC) lathes which offer very high precision. You should also note that in this variety of turning machines, the main components that enable the cutting tool to be fed into the workpiece and the latter to be rotated remain the same. These essential components include the following:
- Turret
- Compound
- Cross slide
- Carriage
- Tailstock assembly
- Headstock assembly
- Bed
Types of Materials that Undercut Pre-Machining Can Turn and Ground
As mentioned, the undercut pre-machining process is compatible with a wide variety of materials (most plastics and metals). The common materials that are used in turning include:
- Titanium
- Zinc
- Brass
- Steel
- Thermoset plastics
- Aluminum
- Magnesium
- Nickel
When you select a material, you must consider several factors. These factors include the material’s machinability, resistance to wear, overall strength, and cost. Although the machinability of a material is not easy to quantify, it is said to possess the following traits:
- Provides trouble-free collection of chips
- Results in a superior surface finish
- Requires minimal force and power to turn
- Promotes extended tool life
To find out more about utilizing the undercut pre-machining process or other machining and grinding services for your coatings, call or email us today!
