From Brass Bars Into Faucets Casting Machining Peeling Grinding And Polishing
From brass bars into faucets
The production of faucets is partly automated, while most work stages are still carried out by hand. Briefly put, the work stages are core building, casting, sawing, machining, grinding, polishing, chrome-plating, assembly and testing. However, a lot of work has already been done before these: a new product has been designed and its production has been simulated on a computer, after which casting has been tested and adjusted until it is perfected. Makes all the tools, shell moulds and core boxes required during casting.
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.
Brass faucet bodies ready for further processing
Faucet bodies are then placed on a conveyor belt, which moves them through automated machining, grinding and polishing processes. The initially produced rough surface is made smooth during a complicated grinding process. The ground metal surface is polished flawless. Finally, employees inspect the level of quality visually and by hand. Small batches of special products may be ground and polished manually. Minor repairs may also be carried out by hand.
Small batches of special products and repairs are still done by hand to ensure flawless result.
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