Full Line Faucet Manufacturing Machine Die Casting Grinding And Polishing

Faucet production process consists of four parts,casting,mechanical processing,surface treatment,and assembly.

1. Casting process

a. Product design

b. Mould design and manufacturing

c. Mould tidy up

d. Mix sand

e. Sand core shooter

f. Low pressure die casting machine

g. Short blasting cleaning out the sand core

h. Sawing cutting

Casting starts from brass bars and cores

The most important ingredient in faucet production is brass, from which the faucet body is made by means of casting. The core is a central part of the production process, as it forms water channels in the faucet body during casting. A solid core is made from fine sand and a hardening agent by heating in a core box.

The core is made from fine sand and it forms the waterways for the faucet body during casting

During casting, the shell mould is dipped into a water and graphite solution. The caster (the person responsible for casting) places the cores inside the mould and removes any loose sand from the shell mould using compressed air.

The cores are placed inside the mould.

The mould is sealed and placed in the blazing hot casting chamber of the casting furnace. Three tons of molten brass flow from the casting furnace into shell moulds. The core maintains waterways open inside the mould, to which technical components are installed and through which water flows through the faucet.

Molten brass flows into the shell moulds.

After brief cooling, the caster uses tongs to move the cast to cool down. Next, the core is removed from inside the faucet body by whirling it in a mill equipped with metal balls.

Faucets are sawn and ground to their final shape

Cooled faucet bodies delivered from the foundry are separated from each other by sawing, and any parts that were necessary during casting but not included in complete faucets are removed.

2.Machining

Get the brass casting after annealing, using CNC numerically-controlled machine tool and other machine tool to process the brass casting,to make it’s dimensional,accuracy,and position meet drawing requirements.

Proceed polish,take outrags,rough surface and potholes on surface,make the product surface have no obvious sand holes and hole defect after completion of machining. Grinding polishing processing, after polishing,use high-speed rotating wheel to grinding workpiece surfaces, make it smooth and bright, increase the brightness of product surface.

3.Surface treatment.

Surface treatment technology mainly include PVD (Physical Vapor Deposition), ORB (Oil Rubber Bronze),electroplating plating etc., most widely used is electrochromism.Electroplate can enhance corrosion resistance of faucet, increasing hardness, prevent abrasion, surface beauty. Most common is hexavalent chromium electroplating,now green trivalent chromium plating is rising. Electroplating can be divided into three layers,first layer acid copper plating,second nickel plating and three chrome plated. International standard of faucet electroplating thickness is 8 microns, the best can reach 12 micron.

Plating surface treatment can be used 24 hours acetic acid salt spray test to judge quality, and can use layer thickness meter to authenticate each metal coating thickness.Usually if coating thickness can reach standard,salt spray test can pass. Electroplating is big pollution and big energy consumption,general faucet factory have to send faucets to professional electroplating factory to plating, thereby increasing production time and difficulty of control.

4.Accessories process

For the shaft,screw nut,screw etc., which used for faucets, need to forge and press from copper bar into copper pieces, and then Processing thread according to the need by machining technician,commonly known as tapping.

5.Assembly

After faucet castings pass the test after plating, then into the assembly process. Assembly is the processing that contect faucet components according to certain order and technology,become a complete set of faucet products, and realize the function of product design process reliably.