PRECISION FINISHED COMPONENTS
Precision finished components, where surface quality and cleanliness are critical, will require the effectiveness of high flow flood washing, often complemented by ultrasonics. Ultrasonics loosens adhered contaminants such as greases, polishing compounds or NDT penetrants to achieve very high levels of cleanliness.
Renishaw is a recognised global leader in metrology, motion control, Raman spectroscopy and precision machining. The complex parts manufactured at the Miskin site are made of various metals and it is vital that any contamination from the production process is completely removed before the components are used in Renishaw systems.
DELICATE COMPONENTS AND SURFACE FINISHES
JK Engineering (JKE), one of the UK’s fastest growing high precision machining companies, turned to MecWash to ensure it had the capability to exceed exacting cleanliness standards for its clients in the Formula 1 and medical component industries.
SAFETY CRITICAL COMPONENT
Swiftool Precision Engineering Ltd is an award-winning sub-contract manufacturing business boasting a range of blue-chip customers in the aerospace, nuclear, marine and petrochemical sectors. Manufacturing high volumes of precision machined components in a range of materials also meant they needed to increase production time without losing quality.
Almost all parts coming out of a turning centre are coated with aqueous or oil based cutting fluids and swarf. Washing is clearly necessary, but the extent of the cleaning process can vary widely depending on subsequent process stages or the degree of cleanliness specified by the customer.
Both MecWash Solo and Duo systems are used extensively for cleaning turned parts. The Solo is used for inter-stage applications or where cleanliness requirements are modest. The Duo provides a higher cleanliness standard with a flood wash to penetrate packed baskets of components, giving a good standard of cleanliness.
HIGH PRECISION TURNED PARTS
High precision turned parts manufacturer Wealdpark work to extremely tight tolerances where even the tiniest microns of contamination can cause a part to be rejected. Using the MecWash cleaning system ensures the finish of parts is spotless and because the wash and dry cycles are so quick, Wealdpark are able to produce extremely high volumes without the wash process slowing down production.
HYDRAULIC AND PNEUMATIC TURNINGS
Stourbridge Turning and Grinding Ltd (STAG) is a leader in its field when it comes to the production of CNC turned, machined and ground components for customers in the global hydraulics, automotive, construction, industrial vehicle and agricultural sectors. With a 30% increase in production, the need to wash the final components in greater numbers and to even higher standards also increased.
Any oil and dirt residue remaining from the production process has the potential to significantly impact the efficiency of electrical components and could therefore adversely affect manufacturers’ reputation. Removing preservative oils, machining lubricants, metal swarf and chips is essential.
MecWash cleaning systems are able to provide the precision cleaning needed, ensuring the electrical components produced are fully clean and dry before the next process, like brazing, is then carried out.
Component cleaning to remove pressing lubricants, machining oils and metal particles is a vital operation in the production process at Clipsal Australia Pty Ltd’s Wingfield plant, one of Australia’s leading manufacturers of electrical switchgear.
DC CONTACTORS AND DISCONNECT SWITCHES
Albright International – a leading supplier of contactors and disconnect switches to industries as diverse as electric vehicles, telecommunication systems, welding machines, railway equipment and marine products – was sub-contracting some of its component cleaning processes but found this was having an adverse impact on the lead times it could offer customers.
OTHER SPECIALIST APPLICATIONS
Although we have outlined many of the larger sectors where MecWash systems are widely used, it is also valuable to recognise that we work with numerous specialist businesses to craft solutions to their specific cleaning needs. A few examples are illustrated in the case studies below.
We are always pleased to talk to customers whose requirements don't seem to fit into the "standard" box and we are happy to invest the time to develop the solution required.
POWER TOOL CASE STUDY
C4 Carbides manufactures tungsten carbide and diamond coated power tool accessories and industrial band saw blades, which are exported across the globe. Effective cleaning plays an extremely vital role in their manufacturing process. The nature of the C4 Carbides products demands that extremely clean surface is achieved prior to applying the tungsten carbide or diamond. Any oil or dirt residue remaining from the production process has the potential to significantly impact the quality of the product, which in turn, could adversely affect C4 Carbides’ reputation.
The Kingston-Upon-Hull based company supplies shot gun cartridges to more than 40 countries around the globe and adheres to rigorous in-house quality control standards to ensure customers get the highest quality and performance cartridges that can propel them to the top of their game. They installed a Duo 400, a highly versatile aqueous cleaning system which works for even the smallest of parts such as the Diamond shot used in manufacturing Gamebore’s cartridges
Bernzomatic – part of the Tools, Hardware and Commercial Products Business Unit of Newell Rubbermaid – in Medina, New York, installed a MecWash cleaning system where the manufacturer’s acclaimed range of hand held blow torches is produced. The MecWash Midi is dedicated to the cleaning of brass parts, including those where blind holes and small diameter apertures are commonplace, many thousands of which are machined each day at the plant and inevitably emerge from this process coated in machining oil and brass chips.