Forger Benefits from Near-net Shape

Utilization of a near-net extruded shape in a forging alloy helped a Midwest forging house increase both the quality and the production rate of a key customer's job. A multiple cavity die is now designed to complete two finished parts in the time spent forging one part with conventional round rod. The use of an extruded brass shape also eliminated a pre-form and a finishing operation that was part of the single-cavity operation. Although the forger reports paying slightly more for a near-net shape, the cost is more than offset through increased productivity and decreased tooling costs!

Complex Shape Eliminates Operations

An extruded brass shape that is cut into components on our precision saws has allowed an East Coast contract shop to eliminate expensive secondary operations for a brake hose fitting. The more complex shaped component is machined complete on a rotary transfer machine. A "hybrid" alloy meets free-cutting brasses machinability, while improving crimping quality. Other critical features include a tightened tolerance in an open-space dimension.

Extruded Piece Cuts Cost of Oxygen

An oxygen concentrator that gives patients the freedom to work or travel, while providing low cost portable oxygen in ambulatory cylinders and stationary delivery systems is available safely and at low cost thanks to an extruded brass housing provided by CXM. The machined housing provides a safe interface between the cylinders and the concentrator. Brass was selected for its "oxygen-compatibility" (resistance to ignition) as well as its high machinability. "We chose an extruded brass profile to reduce waste and save machine time", our customer stated, "It saves in scrap. It only made sense! It was a good economic decision."

Medical Hardware

This near-net shape was selected for use as a rail clamp and regulator block for medical gases. The finished component mounts on a rail system in surgical suites. By providing the extruded brass shape in precision-cut blanks, previous forming and milling operations were eliminated. Corrosion resistance, ease of plating and tight open-space dimensions are critical customer requirements.

Fuel System Streamlined with Brass

An extruded brass T-shape is saving our customer time and money, and may ultimately reduce the cost of diesel truck engines", says a midwest manufacturer of hydraulic & pneumatic valves. "The brass component is used as a fitting and is staked into a metal bracket that's part of the fuel systems for engines," says their OEM sales product manager, "the slotted tab is staked to that bracket. The fact that we don't have to machine everything up to that point saves a major step." Our customer must mill the piece before attaching it to the bracket, but the extruded piece's unique shape eliminates a major machining step in the transformation of the piece into a part of the fuel injection system.This efficiency, which in fact is the characteristic of all brass shapes, saves both our customer and their customer's production time as well as machining costs.

Adapter Fitting Improves Supply Chain

A Y-shaped fitting used in marine engines simplifies the supply chain and reduces total cost for a contract manufacturer, and it's end-use customer. "This is the first extruded brass shape that our customer has used, and they've found great success with it", says Steve Duffy, a CXM sales representative. "The cut–to-length part is difficult to make because of its geometry", Duffy says, "Our customer's engineers designed the part and CXM engineers refined it." This fitting screws into an engine block with the male thread. A knock sensor threads into one of the female ports. The other female port is for clean out.

Because of the compact design, this fitting fits an array of different engines. The fitting's design and unique shape were necessary so that it would not interfere with the other nearby components when installed. This one-piece, Y-shaped brass extrusion replaced a two-piece brazed construction, which had been purchased partially completed. Then, our customer had to finish the part by completing an additional machining step - an assembly and braze operation ending with a leak test. Even though two machining operations had to be added with the CXM extrusion, the elimination of the assembly/braze and test operation resulted in a savings.

Platen Insert Tests CXM Capabilities

A platen insert poses a challenge for CXM because its dimensional tolerances are so tight. The insert is used as a guide for the paper in cash registers and requires stringent tolerances- better than one-half the industry standard. Flatness requirements are also crucial to this component.

CXM has been able to provide a lower-cost product, which has, in turn, helped a metal distributor serve it's customer better.