Case Study of Processing Gaskets for Large-Diameter Flanges | Water Jet Processing for Multi-Hole Flanges
■Overview of Processing Example Product Name: Gasket for Large Diameter Flange Dimensions: Outer Diameter 985φ × Inner Diameter 756φ (P918/22φ-42) This processing example involves the manufacturing of gaskets used for large diameter flanges. The client operates in the plant and equipment sector, requiring stable dimensional accuracy and hole position reproducibility despite the large outer and inner diameters and the presence of numerous bolt holes. T1120 material was used, and by adopting water jet processing, we achieved stable machining of the outer shape and hole arrangement according to the drawings without compromising the material properties. This facilitates easy alignment during assembly and contributes to workability and sealing performance.
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■Product Features (TOMBO No. 1120) TOMBO No. 1120 is a joint sheet made primarily of expanded graphite, with added aramid fibers and NBR. It excels in heat resistance, steam resistance, and corrosion resistance, and has the characteristics of being flexible and resistant to scratches. It is suitable for water, steam, oil, exhaust gases, etc., and is widely used in relatively high-temperature flanges and valves in petroleum refining, chemical plants, and power plants. ■Processing Method (Water Jet Cutting) Water jet cutting is a hydraulic cutting machine that uses high-pressure water to cut materials. It processes by spraying high-pressure water. The injection nozzle can be changed according to the processing material, allowing for the production of high-quality products in a short time. Additionally, the dimensional tolerances that are typically associated with manual processing are significantly improved, resulting in stable processing accuracy. The taper on the cut surface from press processing can also be improved with water jet cutting.
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■Q&A Q. Can you ensure machining accuracy even for large-diameter gaskets? A. Yes. With water jet machining, we can consistently ensure accuracy for outer diameter, inner diameter, and hole positioning even in large-diameter sizes. Q. Can you accommodate shapes with many holes? A. Yes. Based on the drawing data, we can achieve high reproducibility even for multi-hole shapes. Q. Can you handle prototypes or orders starting from one piece? A. Yes. We accommodate prototypes, small lots, and custom shapes. ■Daiko's Capability For gasket and packing machining, turn to Daiko. We provide specific support from material selection consultations to machining method proposals and shape considerations. We also accept prototypes, small lots, and custom shapes, so please feel free to consult with us.
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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.'
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