When I was in high school I joined the school band as a member of the percussion section. I enjoyed the freedom of being in the percussion section. I could walk around in back, and play a number of different instruments as opposed to being contained to one. Most percussionists prefer playing the snare drum and a few the marimbas or xylophone. I however, favored the tubular pipe bells and tympanis. I liked the low boom and ring both instruments produced. Tubular pipe bells have been popularized from the Christmas classic, Carol of the Bells. The vertical bells are also used in the theme of The Exorcist and Futurama. The noise these bells produce sounds similar to church bells.
To play the instrument you must step on a pedal and hit a bell with a hammer. This will vibrate the metal tube creating the desired sound. To muffle the bell you just need to release the petal. I will admit, my fascination with these vertical bells was probably peaked because I think it’s the only instrument you play with a hammer. To make the tubular bells/chimes tube fabricators cut the tubes at different lengths depending on the desired pitch of the tube. Longer metal tubes will have a lower pitch than shorter tubes.
It is possible to make your own tubular bells. First you will need to determine if you want bigger steel tubes or smaller copper tubes. Steel tubing needs to be 0.5 inches thick where as copper tubes only need to be .035 inches thick. Each tube should be cut at a length corresponding to the required pitch the tube will make. Charts can be found online that will provide necessary lengths. However, these lengths are guidelines and further fabrication of a tube may be required to produce the correct note.
After all the tubes have been fabricated, holes are to be drilled at a distance from the top of the tube. The size of the hole doesn’t matter as long as it does not weaken the tube. Next you can string rope through holes to hang the bells up to your liking. You can use this as part of a percussion kit, drum set or even to use as chimes. While playing the tubular bells at school the hammer I used was a wooden mallet with a rubber tip. Something similar to that will produce the best sound.

The post Create Your Own Tubular Pipe Bells first appeared on IQS Newsroom.

Pipe cutters use strong and sharp wheel blades to get better leverage to slice through pipes made out of PVC, copper, Steel, cast iron and many other materials. The blades are easily sharpened by using a common sharpening stone but one must take precautions in order to prevent getting cut. Tube cutting is a processed used to cut tubes to specific lengths depending on the tube’s application.
I’ve had experience with washing a wheeled cutter. However, this was to cut meats and cheeses, not varies piping and tubing. I would have to take apart the meat slicing machine so I can get all the leftover meat out and wash each of the parts separately before I reassembled the machine. I got to wear a chain mail glove on one hand which I always enjoyed. I did manage to cut myself once on my unarmored hand through quick and smart irrational thinking. I saw some meat I forgot to sweep out and grab it without thinking, catching my finger on a part of the blade. Luckily it was only a flesh wound and required no more than a band-aid and a super cool blue finger protector.
I’ve never had to sharpen the meat slicer but I imagine the process is similar to sharpening a pipe cutter (the machines not the hand-help application). To sharpen a pipe cutting first you must remove the blade wheel after unscrew the wheel from the machine. Then cover one side with a small piece of paper towel or a rag. Squeeze the wheel over the paper towel or rag with pliers and sharpen the exposed side with a sharpening stone. Repeat this until the entire wheel is sharpened.

The post To Sharpen a Wheeled Cutter first appeared on IQS Newsroom.

There are many different factors to consider when selecting the right method and corresponding tools to bend pipes. Pipe bending works on straight cylindrical, rectangular or square tubes. The particular tools that should be utilized while bending pipes depends on the size and wall thickness of the tubes as well as the radius of the bend. Common bends include 2-90 degree elbow bends and U-bends such as on a trombone slide. Your budget and quality of bend you’re looking for should also be considered when selecting your bending method.
The first two methods to consider are the Ram and Roll tube bending methods. Ram bending requires a variety of dies and a mandrel or plug tube. Pressure is applied to the tube against one of the dies until the tube forms around the die. The mandrel goes inside the tube to prevent collapse but some bend deformity will appear using the ram method. The roll method requires a variety of spool-like rollers but needs no mandrel or plug and causes little bend deformity. Pressure is applied to the tube as it is fed through the rollers. Different bends can be implemented by putting the tube through multiple times or changing the location of the rollers.
Next is the rotary draw method which requires a mandrel, die and a tube bending clamp block. The clamp will secure the tube to the die as the rotary draw applies pressure. The mandrel or plug is in place to support the pipe cross section. If you have a bigger budget, heat induction creates a quality bend. To bend a tube, an induction coil is heated to the appropriate temperature for the tube material. The coil is then inserted into the tube and force is applied. Air spray or use water to quench the tube after the bend is created.
The last method is an older pipe bending method. Sand packing does what the name implies. The tube is packed with sand and the ends are capped. The tube is then heated with a furnace after which the tube can be bent. Sand acts as a mandrel in this situation. The material of the tools you will use depends on how long you want the tools to last and how much you’re willing to scratch the tube. Steel dies and tools are more durable and will last a while, but the tubes may be scratched in the process. Bronze and aluminum don’t damage the tube but those materials are less durable that hardened or tool steel.

Pipe Bending – Tube Bending Incorporated

The post Tools and Methods of the Pipe Bending Trade first appeared on IQS Newsroom.

Aluminum angles are a sharp angle made from aluminum metal. The angle itself varies on the type of bend created by the manufacturer. Each type of metal bend has its own uses in a variety of industries, including construction, automotive manufacturing, and parts manufacturing. Most aluminum angles are named after letters, while a few others have a different naming system based on their finished shape. The following is a list of some of the most common forms of angles made from aluminum:
U Channels: This channel has an open box shape. The U channel usually has square corners and an open top. These channels are used as railings, construction posts, curtain tracks, decorative trim, joint covers, and in many other places.
J Channels: A J channel looks like the letter “J.” The back side of the metal is much higher than the front side, creating a lopsided shape. J channels are used in a variety of places, including for adjustable table legs, frame supports, lighting strips, and construction projects.
C Channels: A C channel looks just like the letter “C.”  The metal is circular and rounded, and usually has a small opening along one side that makes it possible to slip on and off of an object. You can find C channels used for vacuum cleaner handles, shoe racks, metal grills, fences and railings, and for decorative trim on rounded objects.
Hat Channels: A hat channel looks like an upside down hat. The center of the channel is the basic “U” shape, but the sides of the metal stick out like the brim of a hat. Hat channels are often used to secure objects, and you can find them used to secure loose objects, hold the wheels on a cart, to act as a guide for a sliding door, or to hold wood joints together.

The post 4 Types of Aluminum Angles first appeared on IQS Newsroom.

Sheet metal rings are exactly what they sound like- rings made from sheet metal. Many home-based jewelry makers create rings out of sheet metal that they can polish and embellish to create beautiful, one-of-a-kind creations. If you are interested in making your own inexpensive jewelry, starting with sheet metal rings is a good place to start. You can also use metal rings for a variety of other uses, such as for curtain hangers, 3D art pieces, napkin rings, earrings, necklaces, and anything else you can think of. Experiment with larger and smaller rings for a variety of uses.
Use stainless steel metal for a long-lasting, rust-resistant ring. You can also make rings from aluminum, bronze, silver, or any other kind of sheet metal. Make sure your sheet metal is thick enough to prevent razor-like cuts from the metal edges.
Measure the length of the ring that you want to make using a ring mandrel. If you want to make a ring for another use, simply create a rectangle the same length as the desired circumference of the ring. Cut out this measurement from the sheet metal using tin snips or metal shears.
Use an angle grinder or other buffing tool, such as a tumbling machine, to round the edges of the metal to prevent it from cutting the skin.
Bend the ends of the rectangle together. Use a clamp to hold the two sides of the metal together in a circular shape. Use a soldering gun to solder the two halves of the metal together.
Polish the ring in a tumbling barrel or by hand until the ring has a highly polished sheen on the surface. Add engraving or other embellishments to make the ring beautiful.
Using a similar technique, you can make flat rings for a variety of uses in your home. If you want your rings to have a rounded texture, start with a rod rather than a flat piece of sheet metal.

The post How to Make Sheet Metal Rings at Home first appeared on IQS Newsroom.

The post Splines on a Bike first appeared on IQS Newsroom.

The post How Hollow Extrusions are Made first appeared on IQS Newsroom.

The post Hot vs. Cold Extrusions first appeared on IQS Newsroom.

The post Applications and Benefits of Electrochemical Etching first appeared on IQS Newsroom.

Abrasive flow machining is divided into three categories: one way, two way and orbital.  Four types of abrasives commonly used include: aluminum oxide, silicon carbide, boron carbide and diamond. Aluminum oxide is a blocky mineral substance which is extremely strong and is an economical substitute for diamond. Aluminum oxide is an ideal abrasive choice if the application does not require the abrasive power of the diamond. Aluminum oxide also has very low heat retention which is preferred for these processes. Silicon carbide is similar to aluminum oxide in regards to durability and low cost. However silicon carbide is a better choice for cutting harder materials due to the superior sharpness of silicon carbide. Both boron carbide and diamonds are among the hardness materials on the planet which make them excellent abrasives for this operation.

Photo Courtesy of AZ Industries, Inc.

Flow rates for abrasive flow machining vary based upon the application and materials. For fragile materials it is recommended to use lower pressure which can be preferred for items that may be negatively influenced by friction heat. Typical medium pressures range from 100 – 3200 psi. Research has shown that pressure, flow rate and cycle rate are key factors to the effectiveness of abrasive flow machining. Flow rates are normally .3 to 378 L/min or 3-100 GPM and can last for several hundred cycles. There are however a few disadvantages with abrasive flow machining such as high capital investment but the advantages clearly outweigh the disadvantages if one is in need of a reliable process for interior surface finishing. Some of the paramount advantages of abrasive flow machining are the fact you can deburr, polish, shape and remove material in one process. This operation is more repeatable than methods such as grinding or other forms of abrasion. Abrasive flow machining also easily allows operators to work in hard to reach areas and the overall process is much faster than other process that attempt to perform the same application.

The post Understanding Abrasive Flow Machining first appeared on IQS Newsroom.