How Are Magnets Made?

We talk a lot about magnet tools here. Why not? Magnets are one of the most important industrial tools. They are used for moving and securing work-pieces. Before we delve into the many workings of a magnet tool, let us first talk about how magnets are made. To start with, there are two types of magnets and they are made differently. The first type is the permanent magnet and includes the ones found on refrigerators. There are naturally-occurring magnets such as the lodestone. However, the magnetic field from such magnets is generally too weak for any use outside of classroom lessons. Industrial permanent magnets are made of magnetized ferromagnetic materials such as cobalt, iron, and nickel. The most effective method of magnetizing ferromagnetic materials is heated to a certain temperature to make it lose its permanent magnetic properties. It is then hammered while being allowed to cool in a strong magnetic field to induce magnetism and make it resistant to demagnetization. Demagnetization is a process wherein a magnetic material loses its magnetism. The second type is the electromagnet. It is made by wrapping a coil of wire around are a ferromagnetic material. As electric current is supplied, the coil generates a magnetic field that is further enhanced by the ferromagnetic material. With electromagnets, the magnetic field can be conveniently turned off or on.

Graphite Electrodes And Housekeeping

Despite the various advantages of graphite over metallic electrode materials, it also has downsides that cause many toolmakers to be hesitant, if not outright resisting, in adopting the technology. A major downside to graphite electrodes is that they tend to make a mess.

Just holding a piece of graphite will get your hands very dirty. Machining operations that use graphite electrodes produce a remarkable amount of graphite dust. It can get anywhere. Although graphite dust is not particularly dangerous to humans, they can wreak havoc inside the shop. Electronics are especially vulnerable to graphite dust. Graphite is semi-conductive. It will conduct electricity and cause circuits to short out.

Housekeeping becomes more important and a bigger challenge when using graphite electrodes. It is for this reason that many Asian and European toolmakers continue to resist the adoption of the technology.

All things said it must be noted that there is available technology for controlling graphite dust. Hence, the problem of housekeeping is not impossible to fix. Knowing this, the opposition to adopt graphite is more based on tradition rather than simply wanting a clean room.

Nevertheless, keeping to tradition is not unreasonable or impractical. It helps keeps the operation simple and keeps costs down. Just like with any production facility, adopting a new technology requires operational changes, if not a complete overhaul. The technology for controlling graphite dust requires significant expenditures and changes to the operation and layout of the shop. Most shops cannot afford the inevitable disruption to their operations that happens when transitioning into a new technology or system.

Shop Equipment: Lifting Magnets

Lifting magnets make life inside the shop easier. It makes moving heavy materials easier and safer. Shop technicians don't have to expend so much energy. The energy saved can be directed towards more important tasks. They can focus their energy on technical work. This improves productivity and quality of work. Back and knee injuries from carrying heavy stuff are avoided.

Lifting magnets come in two types. The first one is the permanent magnets. These magnets are quite simple. Their simplicity makes them durable and reliable. A permanent magnet tool does not depend on electricity. This helps keep operating cost down and doesn't require additional electric wirings inside the shop to operate. This makes permanent magnets generally more affordable.

The second type is the electromagnets. The primary advantage of electromagnets is convenience. You can turn the magnet on or off with the flip of a switch and from afar. The electromagnet has more components. More components mean more chances of something going wrong. Also, its dependence on electricity makes it risky. In the event of a power cut, the lifting magnet would stop working. Although the dropping the load can be prevented by securing the load with secondary lifting harnesses, the sudden loss of lifting power can still put personnel in trouble. At the very least, it is definitely not confidence inspiring.

Magnetic Pick Up Tool

Magnet tools are standard in many shops The tools range from magnet boards used to hold workpieces in place during various machining processes to lifting magnets that move heavy metal materials easily and safely. There is also the magnetic pickup tool. You can tell by the name, this type of magnet tool is used for picking up small metal parts. It can be very handy when working on components with limited access and tight spaces. Nuts, bolts, washers, bushings, and even other tools can fall through very tight spaces that cannot be reached by hand. With this tool, you don't have to disassemble an entire case to recover the dropped items.

The amount of weight the tool can pick up varies depending on the product. Some magnetic pickup tools have very high weight capacity and can carry over 7 kilograms. You should not always opt for the high-capacity tools. The reason for this is obvious.

When you are working with metal components all around, the high-capacity magnet will be very hard to control as it will attach to any metal surfaces nearby and becomes very hard to pull off due to the magnetic strength. It can pull off other metal components from their positions. It is better to use the magnetic pickup tool with just the right capacity.

Magnetic Pick Up Tool

Magnet tools are standard in many shops The tools range from magnet boards used to hold workpieces in place during various machining processes to lifting magnets that move heavy metal materials easily and safely. There is also the magnetic pickup tool. You can tell by the name, this type of magnet tool is used for picking up small metal parts. It can be very handy when working on components with limited access and tight spaces. Nuts, bolts, washers, bushings, and even other tools can fall through very tight spaces that cannot be reached by hand. With this tool, you don't have to disassemble an entire case to recover the dropped items.

The amount of weight the tool can pick up varies depending on the product. Some magnetic pickup tools have very high weight capacity and can carry over 7 kilograms. You should not always opt for the high-capacity tools. The reason for this is obvious.

When you are working with metal components all around, the high-capacity magnet will be very hard to control as it will attach to any metal surfaces nearby and becomes very hard to pull off due to the magnetic strength. It can pull off other metal components from their positions. It is better to use the magnetic pickup tool with just the right capacity.

Only Use Nylon Brush For Cleaning Diamond Grinding Wheels

Even fairly new diamond grinding wheels can suffer blunting due to glazing or grime buildup. Glazing is the result of using incorrect speed settings or incompatible work piece material that leads to over-generation of heat. The heat causes the metal binder to soften and move, covering the diamond abrasives. With the diamond abrasives unexposed, the grinding wheel loses its bite.  Grime buildup is caused by dust and filings grinded off from the work pieces that attaches to the surface of the grinding wheel. It has the same effect as glazing in which the diamond abrasives become covered. Unlike glazing, grime buildup is easier to fix. All you have to do is clean the grinding wheel which is a very straightforward task.

In cleaning, what you need is a mineral spirit, cloth, and brush. Soak the cloth with mineral spirit and wipe it on the grinding wheel. The mineral spirit will loosen up the grime. Just wiping with the cloth will remove 90 percent of the grime. For the remaining grime, you will need to use a brush.

In cleaning diamond grinding wheels, many make the mistake of using brass or steel brush. Either of the two does remove grime very quickly. However, the metal bristles of these brushes are too hard and can damage the grinding wheel. These brushes can cause premature wear of the grinding wheel. Use a nylon brush instead. It may not remove the grime as quick, but it helps protect the diamond grinding wheel. If the grime is hard to come out, you can just re-soak with the mineral spirit then brush it again.

Remember, only use a nylon brush for cleaning diamond grinding wheels.

Keeping Diamond Grinders On Point

Diamond grinding wheels and points are expensive pieces of equipment. Premature replacement can be quite costly. Keeping these tools in good condition is very important to minimize expenses and ensure that the tools can be depended on when needed.

Handling. Avoid having the diamond wheels or points from coming in contact with hard objects and surfaces, especially after use. The abrasive surface of the grinders get hot when in use. The heat can weaken the bonding material that holds the diamond grains together. This makes the grinding wheels or points more prone to breaking or deformation when in contact with hard surfaces. This is especially true for diamond grinding points that have narrow tips.

Storage. The tools must be stored in a location with humidity and temperature recommended by the manufacturer. Exposure to humidity and heat can cause the bonding material to deteriorate, causing the grinding wheels or points to wear faster when being used.

Cleaning. Particles from the work piece will cling onto the grinding surfaces. These particles can attract moisture or set off chemical reactions that can damage the diamond grains and the bonding material. Make sure to clean these particles off after using the grinder and once it cooled off.

Settings. Correct RPM settings help prevent overheating which can cause glazing which then renders the grinding surface inefficient or completely unable to cut.