Producing High Quality Rivets with CNC Machines(coloring aluminum Gabrielle)
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- source:BAGANZ CNC Machining
CNC machining offers unparalleled precision, repeatability and efficiency in rivet production. By automating the manufacturing process via digital programming, CNC machines can churn out large volumes of rivets with incredibly tight tolerances. In this article, we’ll explore how CNC technology enables manufacturers to produce superior quality rivets.
Raw Material Selection
As with any manufacturing process, raw material selection is the first critical step in creating quality rivets with CNC equipment. Aircraft-grade aluminum alloys are commonly used for rivets in aerospace applications due to their high strength-to-weight ratio. 2xxx and 7xxx series aluminum alloys provide an optimal blend of formability, shear strength and fatigue resistance.
Other common rivet materials include steel, titanium, copper and various plastics. The raw stock must have uniform mechanical properties and be free of internal defects that could lead to rivet failures down the line. Reputable metal suppliers will provide certified test reports documenting the composition and tolerances of the raw material.
CNC Milling
Once suitable raw stock is procured, CNC milling machines shape the rivet blanks prior to additional forming. A CAD file containing the rivet design is programmed into the CNC controller. Common rivet head profiles include round, brazier, countersunk and modified brazier. The CNC mill uses specialty cutters to achieve the required head contours with tight geometric tolerances.
This machining process also creates the rivet shank by drilling the internal bore. Precision ground carbide drill bits make holes with +/- .001” accuracy. CNC enables fast changeovers between different rivet designs by simply loading new tooling and selecting the appropriate program.
Upsetting
The upset forging process forms the rivet head and compresses the shank, creating a strong post-installation clamping force. CNC upsetting machines use cylindrical dies matching the head profile to forge each rivet blank. Servomotors and ball screws drive the forging dies with controlled force and position.
Real-time monitoring ensures each rivet receives the optimal amount of compression - not too much or too little. The automated upsetting procedure produces uniform clamping force within a 1-2% tolerance compared to around 5% for manual equipment. This leads to greater fatigue resistance and shear strength.
Automated Inspection
Traditional manual inspection introduces variability as quality checks are operator dependent. CNC enabled inspection systems deliver repeatable measurement of key rivet dimensions. Automated vision systems can scan sample rivets and instantly flag any out-of-spec parts.
Certain dimensional checks like shank diameter and head height can even be performed while the rivets are still in the CNC machine via touch probes integrated into the tool changer. In-process inspection saves time compared to offline quality control and gives manufacturers data to adjust processes in real-time if needed.
Packaging & Traceability
To prevent handling damage, rivets are often packaged in plastic bags or cardboard boxes right on the CNC system. Custom dunnage keeps parts securely in place. Barcodes and batch numbers can be printed on packaging or labels to track each box back to the material and production lot. This traceability helps identify potential causes if issues arise down the line after installation.
Benefits of CNC Rivet Production
CNC machines provide numerous advantages over manual rivet manufacturing:
- Tighter dimensional tolerances and less variability
- Increased throughput and 24/7 operation
- Rapid changeovers between different designs
- Real-time quality data for continuous improvement
- Minimal setup waste and reduced machining time
- Automated Assembly integration options
- Improved ergonomics compared to manual labor
With CNC technology, manufacturers can meet the tightest rivet specifications while operating efficiently at high volumes. While upfront programming is required, the long-term benefits for quality, consistency and productivity are substantial. CNC rivet production machines demonstrate how smart automation takes manufacturing capabilities to new heights. The precision engineering of CNC systems will continue driving innovations across industrial applications. CNC Milling