Case study of 3-pass gasket processing | Responding to complex shapes with water jet processing
■Overview of Processing Example Product Name: 3-Pass Gasket Dimensions: Outer Diameter φ990 × Inner Diameter φ960 × t3 This processing example involves the machining of a gasket with a 3-pass structure that divides the flow path. The client operates in the piping and equipment-related field. The product specifications require a configuration that includes a large-diameter ring shape along with internal partition shapes, necessitating reproducibility of the flow path shape and continuity of the seal line. The product feature is the ability to finish the outer shape, inner diameter, and internal shape as a single unit while accommodating the flow path division due to the 3-pass structure. The machining method selected was water jet cutting. This method allows for machining without thermal impact, making it easier to ensure shape reproducibility even for complex shapes, and enables machining of holes, inner diameters, and outer shapes according to the drawings. The effects of the machining include stable dimensional reproducibility of the internal shapes, ensuring assembly compatibility, and contributing to uniformity in finished quality.
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■Product Features 〇D6000 The D6000 is a general-purpose joint sheet made primarily of non-asbestos fibers and synthetic rubber. It excels in processability and flexibility, and it meets the JIS standards for water supply equipment. It can be used as a gasket for general piping and equipment for water, oil, and gas, but it is not suitable for steam lines and is recommended for use below 150°C. ■Processing Method 〇Water Jet Processing 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 processing material, high-quality products can be produced in a short time. Additionally, the dimensional tolerances that were significantly affected by traditional manual processing are greatly improved, resulting in stable processing accuracy. The taper on the cut surface from press processing can also be improved with water jet processing.
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■Q&A Q1. Can gaskets with internal shapes, like those with a 3-pass configuration, be processed? A1. Yes. With water jet processing, we can machine not only the outer shape and inner diameter but also the internal partition shapes according to the drawings. Q2. Is the dimensional reproducibility stable even for large diameters? A2. Yes. Water jet processing improves dimensional tolerances compared to manual processing, resulting in stable machining accuracy. Q3. Can you accommodate prototypes and small lots? A3. Yes. We can handle prototypes, small lots, and custom shapes. ■Daiko's Capability At Daiko, we provide specific support from material selection to processing method proposals and shape considerations. We also accept prototypes, small lots, and custom shapes, so please feel free to consult us from the drawing stage.
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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.'
