Case study of frame gasket processing: Water jet processing for outer R shape.
Processing examples of frame gaskets | Responding to outer R shapes with water jet processing
■Overview of Processing Example Product Name: Frame Gasket (with Outer R) Dimensions: 250□ 25w Frame Material: NBR Rubber Processing Method: Water Jet Cutting This processing example involves the production of an NBR rubber gasket in a frame shape with an R shape on the outer periphery, used in equipment for industrial machinery. This product is utilized for sealing the opening of the equipment, requiring a wide sealing width due to the frame shape and ensuring both safety and ease of handling with the outer R shape. The client is from the industrial equipment manufacturing sector, where dimensional accuracy and shape reproducibility are critical requirements based on assembly with existing equipment. The R specification on the outer periphery is processed according to the drawing instructions, which is expected to prevent snagging at the corners and enhance the safety of the workers. The processing method adopted is water jet cutting. As it is a method that does not use molds, it allows for stable processing of the frame shape, including the R shape, while keeping initial costs low. As a result, reproducibility of the shape, including the outer R part, is secured, contributing to the prevention of interference during assembly and improving workability.
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■Product Features (Material: NBR Rubber) NBR (Nitrile Rubber) is a synthetic rubber with excellent oil resistance, making it ideal for seals in fuel oils and lubricants. It also boasts superior mechanical strength and abrasion resistance, and is widely used in O-rings, gaskets, hoses, and more. However, its resistance to weather and ozone is low, making it unsuitable for outdoor use; it primarily excels in indoor hydraulic and pneumatic equipment. ■Processing Method (Water Jet Cutting) Water jet cutting is a method that uses high-pressure water to cut materials. It processes by spraying high-pressure water. By changing the injection nozzle according to the material being processed, high-quality products can be produced in a short time. Additionally, the dimensional tolerances that are typically achieved through manual processing are significantly improved, resulting in stable processing accuracy. The taper on cut surfaces from press processing can also be improved with water jet cutting.
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■Q&A (Frequently Asked Questions) Q. Is it possible to process a gasket with an outer R shape in a frame shape? A. Yes, it is possible. We can process frame shapes, including outer R shapes, according to the drawings using water jet cutting. Q. Can it be processed without using molds? A. Yes. Water jet cutting does not require molds, allowing for reduced initial costs in production. Q. Do you accommodate prototypes or production from a single piece? A. Yes, we support prototypes and small lots. You can consult us even for projects with small quantities. Q. Is it possible to change to other rubber materials? A. Yes, we can suggest other materials such as EPDM or fluorine rubber depending on the usage conditions. ■Daiko's Capability At Daiko, we provide comprehensive support for special shape gaskets, such as frame shapes and those with outer R shapes, from material selection to processing method proposals and shape considerations. We flexibly accommodate prototypes, small lots, and custom specifications, offering high-precision products through water jet cutting.
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Daiko is a manufacturer specialized in processing various industrial products, including gaskets and packing. With industry-leading processing equipment, including one of Japan's largest water jet cutting machines, and a wide range of materials such as joint sheets, rubber, resin, and metal, we meet our customers' diverse needs. Leveraging the technology and experience we have cultivated over 50 years, we provide high-quality, short-lead-time, and low-cost products to contribute to solving our customers' challenges. To respond to our customers' varied needs, Daiko's production bases are equipped with various processing facilities. Among them, the water jet cutting machines, with a total of four installed at our Osaka headquarters and Tokyo branch, boast one of the largest scales in the country. The maximum processing range is W4,000 × L5,500 mm, allowing for the high-precision manufacturing of large-diameter gaskets and packing. By maximizing material efficiency, we achieve the provision of 'high quality at low cost.'