Manufacturing is a complex activity and requires plenty of planning, design and execution. Product manufacturers have plenty of things to juggle. They have to design the product, source the right materials, manufacture the product, and perform quality assurance tests, package and ship it. Tackling all this by yourself can feel like a herculean task.

Worry not, this is where we come into the picture. As one of the top contract manufacturers in India, we help you at every step of the manufacturing process. Whether you’re trying to reduce the time of your product manufacturing cycle or cut down costs, we can help you out.

With Alok Tools, you don’t have to deal with the myriad manufacturing challenges all by yourself. As a trusted contract manufacturer we help you make production as smooth as possible so that you can focus your efforts on your core business practices.

In this guide, we walk you through the top 10 benefits of hiring Indian contract manufacturing companies. With a trusted contract manufacturer by your side, you can produce high-quality, market-ready products while keeping down overhead costs.

10 Benefits of Hiring a Contract Manufacturer in India

Even if you have the necessary manpower, resources, and experience to handle manufacturing in-house, there are certain benefits of outsourcing your manufacturing process. Here are the top ten benefits of why you should hire contract manufacturers.

1. Produce High-Quality Products

One of the biggest benefits of outsourcing manufacturing is that contract manufacturers have the expertise to create high-quality products. They have a team of skilled product engineers, quality testers as well as advanced manufacturing tools like 3D printers, precise cutters, and drillers, milling instruments, CNC machines, and more.

Result: You get world-class products that are more functional and aesthetically appealing.

2. Reduction in Manufacturing Costs

When you outsource your manufacturing needs to a contract manufacturer, you don’t have to invest in expensive manufacturing equipment or hire machinery operators, warehouse maintenance staff, product engineers, etc. The contract manufacturer handles it all for you.

From sourcing raw materials to labelling and packaging the final product – your contract manufacturer handles it all for you. This helps you cut down on overhead costs, which in turn, results in significant savings.

3. Stay within Project Deadlines

One of the biggest challenges of in-house manufacturing is that there are several unknowns. Machine breakdown, staff leaves, difficulties in procurement – any single factor can delay and derail the entire process. However, when you partner with a trusted contract manufacturer, you are guaranteed that the project will be completed as per the agreed timeline.

4. Reduce Manufacturing Time

This is one of the main reasons why even big companies hire contract manufacturers in India. When you outsource manufacturing, it reduces manufacturing time. CMs (Contract Manufacturers) have advanced tools to reduce the time taken to produce a product. You can get your products on shelves within just a few weeks, if you desire so.

5. Save Resources

Contract manufacturers help to save resources in two major ways:

• By using lean manufacturing techniques, you can cut down on wastes generated, which in turn, translates to more savings for you. It also helps you lower the carbon footprint of your business, improving your sustainability practices.
• Save the precious time of your resources. Instead of focussing on manufacturing details, your team can spend time on other important tasks like lead generation, conversion, branding, marketing, product improvements, etc.

6. Operate with a Lean Team

Manufacturing is a labour-intensive process. It requires a large team of: engineers, machine operators, skilled workers, plant managers, warehouse staff, etc. When you work with a contract manufacturer, you get to enjoy the benefits of a large workforce without worrying about payroll management, shift scheduling, etc.

7. Scalability

Scalability is one of the other primary benefits of contract manufacturing. You can increase (and even reduce) manufacturing capabilities as per market demands. You don’t have to invest in additional machinery and staff if your product volumes increase. Similarly, you can reduce product quantities if needed, without worrying about keeping staff and machinery idle.

8. Perfect for Small Businesses and Startups

Contract manufacturing levels the playing field. By reducing manufacturing costs and time, it makes it easy for small businesses and startups to get their products into the market cost-effectively. It helps small businesses compete against the bigger corporations, without compromising on the quality of products.

9. End-to-End Services

Contract manufacturers handle it all. This includes prototype design, material sourcing, manufacturing, assembly, packaging, labelling and shipping. Keeping the entire process from start to end under one roof cuts down costs significantly.

10. Gain an Edge over your Competitors

When you partner with an experienced contract manufacturer in India like Alok Tools, you get more out of the partnership. We are not just your manufacturing partner. But, we also guide and assist you with vital knowledge that can help your product stand out in the market. With years of experience in manufacturing, we have a thorough working knowledge of the industry. Our insights will help you gain an edge over your competitors.

How to Identify the Best Indian Contract Manufacturing Companies?

Now, that we’ve seen the advantages of contract manufacturing, let’s focus our attention on how to select the best contract manufacturing partner for your niche.

The right contract manufacturer streamlines the manufacturing process from start to finish. They help in reducing production time and costs, giving you a world-class product that is designed to stand out.

While selecting your contract manufacturing partner, look for a company who offers you end-to-end service. Your partner should be able to handle it all. Right from sourcing raw materials to offering design suggestions to handling packaging and shipping. The best contract manufacturers in India walk you through every step of the process.

They don’t see you as yet another client, but a partner. They offer value-added services like advice on material selection, design feedback, and more. Look for a contract manufacturer who has been manufacturing products under their brand. This is key, as it helps you get a clear idea of the quality and standards of their manufacturing.

With an experienced manufacturing partner by your side, you can produce world-class products and emerge as a leader in your industry. So, what are you waiting for? Outsource your manufacturing need and deliver groundbreaking products and capture the market!

These lines are created by a manufacturing finishing process known as knurling. Knurling helps to create any combination of vertical, horizontal, or crisscrossing lines on the surface of a workpiece. Knurling can be done either using a machine like a lathe or by hand using the right tools.

How does knurling work?

Knurling doesn’t add any material. Rather, it creates a rough texture by removing or cutting away some of the material. Knurling tools have a specific pattern. This can be either horizontal, vertical, or a combination of both. When the knurling tool is pressed against the workpiece, the pattern on the tool is replicated on the workpiece.

Knurling tools have a “V-shaped” tooth. It’s created by displacing the material on the workpiece. When the knurling tool is pressed against the surface of the rotating workpiece, it creates the required pattern.

Knurling tools can produce the following patterns:

Straight – horizontal or vertical lines

Diagonal lines

Diamond patterns

Applications of Knurling

Knurling has a huge range of applications in daily use. It’s primarily used for:

Decorative purposes

Serration surfaces that are keyed or locked together in unit assemblies

To improve the grip of hand tools

Consumers love having a textured finish rather than a smooth finish. This is one of the main reasons why knurling is used on a product, to enhance its aesthetics. It creates an attractive pattern on the surface of the workpiece.

Besides aesthetics, knurling is also used for other practical purposes like improved grip. Hand tools like hammers, wrenches often have a knurled handle to improve stability and performance while using it. Here’s an example. Consider a hammer with a smooth handle. The smooth surface is prone to slipping easily, leading to accidents. On the other hand, consider a hammer with a textured handle. The knurled handle protects against slippage, helping users have a steady grip.

Hand Vs Machine Knurling

Knurling can be done either by machine or hand. Hand knurling uses a rolling roll that creates the desired pattern on the workpiece. Machine knurling uses a lathe to cut the desired pattern on the workpiece.

Hand knurling is the most basic knurling process and doesn’t require large machines. It can be completed with a simple roller tool. Hand knurling creates the patterns primarily uses pressure. When the worker runs the knurling tool across the surface of the workpiece, it creates a textural indention on the object. Machine knurling, on the other hand, creates the texture by chipping away a small portion of the material of the workpiece.

Check out the knurling tools from Alok Tools:

Quick Acting Knurling Tool

This is a knurling tool that is easy to set up. It minimizes the pressure on the lathe, crossfeed, or center screw. The depth of the knurling impression can be set based on the production work. It creates medium diamond-patterned knurls in the following size:

¾” x 3/8” x ¼”

Besides our quick-acting knurling tool, we also offer knurling tool holders and spare knurls for knurling tool holders.

If you require more info on our range of knurling tools or need help finding the right set of knurling tools, drop in an email to sales@aloktools.com, and our team will get back to you with the required information.

Step 1: Familiarise yourself with the Different Types Available

Tap wrenches can be classified into two types:

Double-end Adjustable Wrenches – It has a threaded handle that is fixed to a clamp. It’s used on larger taps where there is adequate room to turn the larger wrench. They are also called as bar wrenches.

T-handle Wrenches – It has a collet that secures the tool. T-handle wrenches work well for small spaces that require an extra reach.

At Alok Tools, we have the following styles of tap wrenches to suit various needs:

Ratchet Tap Wrench

It comes with a smooth, chrome-plated body and is a handy tool to include in your toolset. It works using the reversible ratchet mechanism. It works with taps and other tools that need to be turned by hand.

Adjustable Tap Wrench

It’s a high-quality tool used for hand tapping operations. As the name implies, it comes with tempered and hardened jaws, adjusted to suit various applications. You can comfortably use it with screw extractors, reamers, and other standard tools.

Extra Long Tap Wrench

It has an extra-long handle of 33cm, making it ideal for spaces that are hard to reach. The handle can be extended to ensure better leverage. The tempered and hardened jaws make it robust and long-lasting. It has a shiny, chrome-plated finish.

T-handle Tap Wrench

This is a general-purpose tap wrench that can be used for various hand-tapping operations. The handle has a heavy knurled cap that offers a firm grip. It’s an ergonomic and high-quality tool that works well for DIYers as well as professionals.

Step 2: Assessing your Needs and Figuring the Required Size and Shape

The next step is to decide if you need an adjustable tap wrench or a fixed one. Adjustable tap wrenches can accommodate tool heads of varying sizes. However, they are not as strong as fixed tap wrenches. That doesn’t mean one type of tool is better than the other. It all depends on your usage.

If you’re looking for a tap wrench to help you with small DIY projects around the house, then we recommend purchasing a couple of adjustable wrenches to cover all your size requirements. On the other hand, if you’re looking for tap wrenches for bigger and professional projects, you can invest in fixed tap wrenches.

The number of wrenches you need to invest in depends on how often and the type of jobs you will use them. If you’re looking for wrenches for home use, then a couple or more wrenches in standard sizes are sufficient. If you’re a professional, then investing in a complete set of fixed and adjustable tap wrenches will help you carry out all tasks with ease.

Step 3: The Measurement Type

Wrench heads are either measured in metric or US standard sizes. Metric measurements use millimetres, while US standard sizes use inches. At Alok Tools, our wrenches are marked in mm. If you require wrenches in US standard sizes, get in touch with our team, and we can help you out.

Step 4: Understanding the Materials used

The materials used in the tap wrench play a crucial role in determining its durability, aka how long the wrench will last. Materials like chrome plating offer longer durability and ensure much better corrosion resistance. The highest quality wrenches are made with chromium-vanadium. While cast iron and wrought iron wrenches provide outstanding durability, they are prone to rusting. So, opt for wrenches with chromium-finish.

Final Thoughts – Try our Tools

Now that you’re aware of the different types of tap wrenches and how they work, you can choose the right tool for your specific needs. Sometimes you may feel that you need to try out a tool before you purchase it. Trying out the tool can give you the confidence that it’s the right one for the task. Get in touch with us to discuss your requirements and see if we can arrange a trial.

If you require any further help, don’t hesitate to contact our tool experts at Alok Tools, India’s leading industrial hand tools manufacturer and exporter.

The Three Common Types of Vices include:

1.  Machinist Vice

It’s an excellent multi-purpose holding tool and is one of the most popular vice types. It has a flanged bottom that has a larger surface area. The large surface area helps to stabilize the vice and paves the way for convenient clamping to the work table.

However, one of the significant drawbacks of the machinist vice is that it occupies plenty of space. If your work table is small, then you can opt for other types of vices like the CNC or Toolmaker vice. Here, at Alok Tools, leading industrial tools vices manufacturers in India, we supply high-quality machinist vices that are lock-down, meaning the moveable jaw is fixed steadily to the work table and doesn’t rise, while the screw is fixed.

2. CNC Vice

The CNC vice overcomes the drawbacks of the machinist vice. The design of the CNC vice is compacter, and it offers a rigid holding compared to the machinist vice. The smaller design of the CNC vice means that you can use multiple vices on your work table, without having to worry about the availability of space.

CNC vices can be clamped either horizontally or sideways. However, the one drawback of CNC vices is that they don’t have a flange. Lack of flange makes it tricky to secure them steadily to the table. However, this drawback can be easily overcome by using special table clamps that are supplied with the CNC vice. At Alok Tools, our range of CNC vices feature a lock-down design, improving their hold.

3. Toolmaker Vice

Compared to the other two types of vices, toolmaker vices are smaller, more accurate and inexpensive. However, they are cumbersome to use. The tightening is achieved by a multi-step latch instead of a single screw used by the other vices.

Toolmaker vices are used for jobs that require the workpiece to be moved from one machine to another. It’s easy to leave the work in the toolmaker vice and move it to the next machine, without disturbing it. While toolmaker vices have a lock-down design, unlike the other two types of vices, it doesn’t come with replaceable jaws or work stops.

Now, that you are aware of the three common types of vices, let’s take a look at,

How to Select the Right Vice for the Job?

While it may appear easy, selecting the right vice for the job can be tricky. Worry not, here in this guide, we share with you a few factors to consider so that you can choose the right metalworking bench vice for the job.

• Depth of the Vice

The first factor to consider is the throat depth of the vice. The throat depth is the distance between the top sides of the jaws to the top side of the slide below the jaws. A large throat depth means you can hold larger workpieces.

While selecting a vice, make sure to unwind the screw to its fullest so that you can get a clear idea of the maximum throat depth of the vice. If you work with large objects, then choose a vice with a bigger throat depth is highly recommended.

• Size of the Objects to be Used

This is an extension of the above factor. Make sure to consider the average size of the objects that you usually work with. Larger objects require a vice with a larger jaw width. Generally, the jaw widths of vice are measured in inches and it ranges from 4, 5, 6, 8 and so on.

• Weight of the Vice

Another factor to consider is the overall weight of the vice. Two vices with similar jaw widths may vary in weight. So, make sure to consider the weight of the vice while choosing. Check whether your workbench can handle more massive vices that weigh more.

• Vice Usage

Finally, you need to consider the intended usage of the vice. How will you use the metalworking bench vice? Will you use the vice as an anvil and hammer over it? If yes, then you need to ensure that you pick a sturdy vice that can handle this abuse. Vices with a sizeable rear anvil work well for hammering.

Select the Right Vice that is perfect for your Requirements

Make sure to consider all the factors mentioned above, while choosing a metalworking bench vice. With that said, there are plenty of vices available in the market. You may have to browse through multiple types, specifications and more.

If you’re confused about which is the right vice for you, you can always get the help of our tool experts, here at Alok Tools, one of the best tools manufacturing companies in India. With a wide range of industrial and hand tools, we supply our customers with the best quality tools at the most affordable prices. To know more, get in touch with us.

First, a quick introduction on,

What are Vices?

Vices are holding tools that are used in machines like drilling machines, milling machines, lathes and more. It’s used to hold a workpiece securely during a specific task. Design-wise, there are three primary types of vices, like:

Plain Vice

It’s the most common type of vice and is mainly used for milling operations. It’s mounted directly on the machine table. It’s fastened to the table with jaws. The jaws are either at right angles or parallel to the table. The workpiece is attached firmly between the fixed and moveable jaws.

Swivel Vice

As the name implies, this vice has a swivel operation. The workpiece is milled at an angular surface, without moving it. The base of the swivel vice is clamped to the work table using T-bolts.

Universal Vice

The universal vice is highly versatile. It can be swiveled at a horizontal plane just like the swivel vice. Additionally, it can also be tilted in a vertical position to make way for angular cuts. It’s mainly used by toolmakers and hence is known as toolmakers vice.

Modular Vice from the House of Alok Tools

As the leading machine and modular vice – manufacturers, suppliers, and exporters in India, Ozar Tools, the global tool brand from the house of ALOK INTERNATIONAL PVT. LTD. offers a wide range of machine vices suitable for various applications. Our bestselling product categories include:

• 2-way swivel and tilt vice – precision
• 3-way swivel and tilt vice – precision
• 3-way unigrip drill press vice
• Bench vice
• Drill press vice – multi-side use
• Engineers steel bench vice
• Milling vice – self-centering
• Offset steel bench vice
• Precision drill press vice
• Precision milling machine vice
• Precision toolmakers steel vice (Pin Type)
• Precision toolmakers steel vice (Screw Type)
• Unigrip drill press vice
• Welders corner angle vise clamps
• Woodworking vices
• Modular vices

Closer Look at the Features and Highlights of our Modular Vices

Designed for precision milling and grinding, our modular vice is perfectly suited for standard and CNC milling machines. It can be used to work individually or set up as part of a series along with other modular vices. The moveable jaw is made of high-grade hardened special alloy steel. It is hardened and stabilized to ensure durability and quality.

Available Sizes and Dimensions

Salient Advantages of Modular Vices from Alok Tools

No Wear
As we manufacture with the highest quality materials, our vices have the most robust structure. All our vices and accessories are made using case hardened HRC 60 ±2 special alloy steel. Thereby offering the best performance, maximum rigidity and no signs of wear and tear. We offer a standard product warranty on all our vices and associated mechanical components.
High Accuracies up to ±0.2mm
The modular vice offers precision alignment along with the machine axis, thereby enhancing the quality of the output.
Quick Clamping
The clamping action is completed within minutes, thanks to the sliding clamping device. Thereby making it super easy to use.
Modularity
All our vices and accessories are modular – meaning components can be interchanged with different work holding systems in perfect alignment.
Handy, Space-Saving Design
The design of the modular vice is such that it can be moved easily, in spite of having a solid construction. It allows for easy movement from one machine to another.
Safety and Rigidity
Both the jaws (fixed and moveable) and built as one solid piece. There are no additional key-nuts or slides. Hence, the jaw has higher rigidity, and there is no bending. Also, the jaw plates are manufactured at a pull-down angle. This ensures that during the clamping operation, the workpiece is held at a precise angle, and there is no chance of injury.

For more details regarding the tool – features, applications, prices and more get in touch with our expert sales team. Also, Alok Tools has an exclusive distribution program, where we partner with overseas vendors to supply quality industrial and hand tools at the best prices in the market. Drop us an email or give us a shout out on social media to know more.

Having a bench vise is like having an extra pair of sturdy hands, to help you with your metal and woodworks. And, finding the right bench vise offers you not only better outputs but also helps you complete the work with precision.

What does a Bench Vise do?

When attached to a sturdy workbench, the bench vise helps in holding the workpiece still and free from vibrations. This, in turn, helps you enjoy steady plane strokes, smoother saw cuts, and better sanding. Though the majority of industrial workers (both metal and woodworkers) rate bench vises as an indispensable tool, sadly, it’s one of the most underrated tools in the factory floor.

Using the wrong bench vises affect the quality of the work. By investing in the right bench vise, you can keep your work steadier and complete it faster. Now, that you realize how critical the humble bench vise is to your woodworking and metalworking, it’s time to select the right one that works for your shop.

Understand the Types of Vises:

• Metalworking vices

This type of metalworking vice is made to clamp metal and is ideal for clamping any large, heavy materials, due to its strength and ability to withstand pressure, which is a result that prevents the work from slipping.

Free your hands for your work by using these vises to firmly grip your workpiece during cutting, drilling, welding, scraping, sanding, and other tasks. They have adjustable jaws that clamp onto the workpiece for a secure hold. Select a vise based on the type of material of the workpiece, the jaw capacity you need for your material, and the desired mounting style.

Secure your metal workpieces for grinding, cutting, filing, and other metalworking processes with these heavy-duty vises. They’re built to withstand frequent use and provide a strong grip under pressure from heavy materials. Ideal for machine shops, metal fabrication, automotive repair, and other industrial settings.

Here, at Alok Tools, our bench vises use a toe-in-design. This means the outer jaw tilts slightly inward to apply the greatest pressure at the top of the jaws, where it’s most needed.

Woodworking Vices

Help prevent marring or scratching the wood, plastic, and composite materials by using these woodworking vises. They have smooth jaws with a wide, flat face that distributes clamping pressure across the surface of your workpiece for a firm, yet gentle hold.

Wood often needs to be clamped when completing tasks such as sawing, drilling or carpentry. This is so that the user can keep both hands free and away from the material during applications, and so a woodworking vice is an ideal tool to use in these situations.

The jaws of woodworking vices are also very broad, which avoids cracking the wood as the clamping load is distributed over a large section of the workpiece.

Other Bench Vises include:

• Welder’s Corner Angle Vice Clamps
• Woodworking Vises
• Precision Tool Makers Vices – Screw Type or Pin Type
• Drill Press Vises
• Milling Vices
• 2-Way and 3-Way Swivel and Tilting Vices
• Shop Bench vise

Which Bench Vise Should I Buy?

Sometimes selecting the most suitable type of bench vise can be challenging. Here are some factors to guide you, while choosing the right vise:

1. Throat Depth of the Vise

This is one of the main factors to consider. While selecting a bench vise, you have to check its throat depth – this is the distance from the top side of the jaw to the top of the slide below the jaw. Larger throat depths mean you can hold larger workpieces.

2. The Jaw Width of the Vise

Bench vises have varying jaw widths. For larger objects, you need bench vises that have bigger jaw widths.

3. Use of the Vise

Finally, you need to consider the usage of the bench vise. How do you plan to use it? Depending on the usage, you can pick a bench vise that serves the specific purpose.

For instance, if you frequently remove and hold different sized workpieces, then look for vises with quick release opening mechanism. This way, you don’t have to wind and unwind the lead screw every single time manually, you are changing the workpiece.

Still, need help picking out the right bench working vise? No worries, here at Alok Tools our expert tool crafters can help you pick the right tools that work for your specific applications. Get in touch with us and pick the best bench working vise for you.

Here, in this post, we share with you some maintenance tips to keep your pneumatic tools running for years to come, without any troubles.

Handle your Tools with Respect

Yes, it’s true that pneumatic tools are made to work in harshest environments. Here, at Alok Tools, leading Industrial Pneumatic tools manufacturer in India, our range of air tools are made with high-quality hardened metals that are tough and resilient to keep working day-in and day-out.

With that said, even the sturdiest tools have a breaking point. It can fail because of wear and tear or due to improper handling. As pneumatic impact wrench manufacturers, we have observed that anvils are the most commonly damaged parts in impact wrenches and ratchets. This is because anvils are always under heavy torque and pressure, which in turn, causes steel fatigue.

When it comes to tools like ratchets, grinders and drills, gears are most likely to fail, when the user adds too much load to the tool.

To ensure your pneumatic tools last for long, here’s one basic thumb rule that you have to follow:

“Always use the Right Air Tool for the Right Job.”

For instance, using small impact wrenches for larger models causes breakage due to overstressing. Remember that each tool has its limits. Always refer to the manufacturer’s instructions regarding usage limits.

Handle your Tools with Care

In an ideal world, air tools will be stored in the right storage boxes both before and after usage. However, the reality of the industry floor is different – air tools are carelessly tossed or dropped. And, sometimes air tools even get run over by forklifts.

When an air tool is dropped, it could cause the internal mechanisms to break or misaligned. For instance, dropped wrenches fail to turn and compressor lines may leak. You may be able to repair dropped tools or it may be impossible to repair it.

To avoid such situations, follow this basic rule,

“Always have a flat resting area for pneumatic tools.”

Make sure that you instruct all factory workers to place tools only on this place and not on the factory floor. You can even add some shock-absorbing soft padding to the resting place, to prevent tools from slipping off. And, ensure that all workers are trained not to throw tools around. It’s not just harmful to the tool, but could even lead to injuries to other workers.

The Importance of Right Lubrication

Just like all other tools, pneumatic tools require regular lubrication and oiling. Without lubricants, the internal tool parts will start to grind against one another. This causes friction, erosion and wear and tear.

There are two main reasons for air tools to fail:

1. Lack of grease and oil
2. Water in the airline

Make sure that you use the right lubricant specified by the manufacturer. To find out more about the different types of lubricants and help to choose the right lubricant, check this post. Also, use the right lubricating tool to prevent oil from seeping all over the delicate internal components. Make sure that the lubricant you use doesn’t get into the airline.

The rule of thumb to follow here,

“Always oil air tools at the end of the work day.”

The inner components of air tools are made of steel and are prone to rust. Oil tools at the end of the work day, and run it for a few seconds. By doing this, you ensure that the lubricant stays in the tool overnight, and protects it from moisture.

Keep Your Tools Clean

Just like oiling, you have to ensure that pneumatic tools are kept clean at all times. Dirt build-up, dust accumulation, water-caused corrosion is a big No-No. To clean tools, all you have to do is wipe grime and moisture off it using a clean cloth.

The rule of thumb here,

“Don’t let dirt, dust or water accumulate on your air tool.”

If water enters the tool, you have to ensure that it’s dried off quickly. After drying the interiors, you must relubricate it. Check the tool’s service manual for instructions. Make sure to store your pneumatic tools in water-proof and air-tight containers to prevent water and dust from getting into it.

Here are some Common Problems of Pneumatic Tools with Causes and Remedies

#1: Tool runs at normal speed, but loses speed or power midway or under load.

Possible Cause – Motor parts or the cam clutch could be worn down. Lack of lubricant.

Remedy – Lubricate the internal clutch housing. Make sure that the clutch case is not completely full. Overfilling can cause slowing down of clutch parts.

#2: Tool gets Heated up Quickly during Operation.

Possible Cause – Indicates insufficient grease.

Remedy – Proper lubrication.

#3: Tool runs slowly.

Possible Causes – Air flow could be blocked due to dirt. Power regulator could be closed. Motor could be jammed with dirt.

Remedy – Pour lubricant into the air inlet as per manufacturer instructions. Operate the tool in short bursts to dislodge dirt and dust.

#4: Tool does not run.

Possible Causes – Stuck up motor vanes.

Remedy – Pour lubricant into the air inlet as per manufacturer instructions. Operate the tool in short bursts to dislodge dirt and dust. Disconnect power supply and tap the motor housing gently. Try to free the motor by driving shank manually.

#5: Tool does not turn off.

Possible Causes – The “O” rings could be dislodged from the inlet valve.

Remedy – Replace the “O” ring.

If you are not able to troubleshoot on your own, it’s highly recommended that you contact the tool manufacturer or an authorized service center.

The Bottom Line

Whether you are a floor technician, general manager or a foreman, make sure to follow all the maintenance tips here and keep your pneumatic tools functioning for years to come. And, for the best Pneumatic Machine Tools in India, look no further than Ozar-Toku air tools.

You’re in luck, here in today’s post, we show you the benefits of applying the right lubricants in the right way to your tools. Let’s get started.

Introducing Minimum Quantity Lubrication (MQL)

As the name implies, minimum quantity lubrication is a process of applying lubricants directly onto the interface of the cutting tools. This process is highly advantageous for various industrial processes like sawing, drilling, milling, turning and tapping.

By switching over to MQL, industrial plant owners see a huge reduction in their overall operational costs. Here are the top benefits of MQL:

• Extended tool life
• Decreased maintenance
• Increase in machine uptime

Let’s take a look at the three critical elements for successful lubricant application.

Factor No.1: Choosing the Right Lubricant

Choosing the right lubricant plays a crucial role in extending the lifetime of your industrial tools. Finding the right lubricant for your tool depends on several factors like tool type, tool material and tool manufacturer. Check out the manufacturer manuals to find out if there are any specific lubricants recommended for your tools. If yes, make sure you use the recommended one.

Here are a few factors to keep in mind, while choosing lubricants for your tools. Oil-based lubricants work better than water-based lubes for covering a metal surface. Furthermore, not all oils work the same. Organic oils are better lubricants compared to mineral based oils. Polar molecules have opposite electrical charges at either end, which in turn, creates a thin consistent bond between the metallic surface and the lubricant.

Additionally, look for lubricants that are highly stable and prevents oxidation of the metals, thereby preventing rust formation on the surface of your tools.

Factor No.2: Finding the Right Mode of Lubricant Application

Successful application of a lubricant plays a crucial role in extending the life of your industrial tools. You need to apply the lubricant precisely, for it to do its job effectively. You need to ensure that the lubricant gets right in between the cutting edge and the workpiece.

Using too little lubricant causes an increase in friction, which in turn, increases the heat buildup in the tool. On the other hand, if you use too much lubricant, it not only increases lubricant expenditure but could also lead to premature tool damage.

In MQL, your goal is to ensure that you maintain a thin film of lubricant along the cutting interface. Some tools require tools with multiple nozzles or specific configurations to ensure that the lubricant is applied uniformly, along with the cutting interface.

For instance, lubricating drilling tools is difficult, as it’s hard to maintain a consistent film of lubricant along the drill holes. In such cases, you need a specially designed spindle applicator to ensure that the lubricant is spread uniformly along the tool’s interface.

While choosing a lubricant application system, look for systems that can deliver fluid in a consistent and precise manner. Positive displacement pump applicators work more consistently compared to venture-type lube applicator systems.

Additionally, look for systems that mix air and oil equally to maintain consistent fluid delivery. The best lubricant applicators hold air and oil separately and mix them only before application. Also, don’t forget to consider the air flow in the system. Too much air flow could cause the applicator to mist up. Ideal applicators use only enough air that gets the oil to cool, without causing misting of the lubricant applicant.

Factor No.3: The Machining System

To achieve the optimal effects of lubrication, you have to consider several elements including – the lubricant applicator, proper tooling, and chip evacuation. All these factors must work cohesively to ensure that your tools are properly and adequately lubricated.

Final Thoughts

With the right lubricant, the right application, and the right machining system, you can see an incredible increase in tool life, while reducing your overall operational costs and keeping your plant clean.
If you have any doubts regarding the right lubricants for your tools, don’t hesitate to get in touch with our tool experts here at Alok Tools, India’s leading lubrication tool manufacturer.

We would like to begin this week’s post, with an age-old saying that you would have heard countless times, “You get what you pay for.” The value of any item, be it big or small is determined by the price we pay for it.

The industrial tools you use at your factory or plant are no different. Sadly, most businesses fail to realize the huge impact of these small tools in the overall operation scale. We often see, businesses allocating a huge amount of their budget to purchase new machinery or equipment.

It’s rather unfortunate that these businesses don’t spare a second thought to purchasing the right tools that they will use to operate their machinery. After all, remember that your machines are only as good as the tools you use to operate them.

Here, in today’s post, we explore the true cost of your industrial tools and take a look at the reasons why you should invest in high-quality tools.

Enter the Good, Better, and Best Philosophy of Choosing Industrial Tools

Here, at Alok Tools, we use a good, better, best principle to help you choose the best tools for each application.

Here are three questions to consider while purchasing industrial tools:

• Should you choose the cheapest tool available on the market, in an attempt to cut down costs?
• Or, should you go for the better option in the hopes that it will help you carry out your tasks efficiently?
• Or, should you invest in the best tool in the market so that you get high-performance and high-quality outputs?

If you were to ask us, we suggest that you choose the best tools, to improve your outcome significantly. When you choose high-quality tools, you are not just boosting performance, but also ensure that the tool lasts for a long time.

Remember that best doesn’t equate to costliest always. Brands like Alok Tools provide high-quality tools at affordable prices.

So, how do you compare and evaluate Tools from Different Manufacturers?

This is where Cost-per-part comes into the picture. It’s a simple but effective benchmark used by engineers and estimators to determine the right tool for their business.

What is Cost-Per-Part?

Simply put, this is a numeric measure that calculates the sum of all manufacturing inputs to give your hourly rate. It considers all expenditures like statutory costs, labour, capital equipment financing, raw materials, energy overheads and tooling to determine the final output.

The cost-per-part evaluates the total sum of all costs against the total output for a given period. When it comes to tools, you need to look for tools that offer you the most returns for your investments. This is why it’s essential to consider cost-per-part.

Factors that Determine the Life of a Tool

The tools you use to play a crucial role in influencing the output of all your machines. While purchasing industrial tools, you have to look for tools that have a long life. Several factors play a huge role in determining tool life. They are:

• Material

Aluminium and low carbon steels are soft and pliable compared to other commonly used alloys like INCONEL and titanium. If your machines are made from hard materials, then it takes a toll on the life of your tools.

• Tool Holding and Clamping Style

When using tools, you should aim to reduce unwanted movement and vibrations to extend tool life. By using high-quality TIR precision holders, you reduce premature damage to your tools.

Don’t forget to Consider the Hidden Costs while Choosing Tools

Very often, businesses choose tools that are just “good enough,” because of the low initial costs. They fail to consider the hidden costs of purchasing low-quality tools.

• Downtime

When you choose low-quality tools, they are likely to break down. This means, your processes get interrupted which in turn increases downtime and labour costs.

• Tool Failure

Low-quality tools are susceptible to breaking down mid-way through the process. This causes damage to raw materials as well as impacts the output of the process.

• Cost of Replacement Tools

When you are replacing tools frequently, you have to consider the cost of the replaced tools along with your initial investment.

Considering all these factors, you can easily find that paying a bit more for higher quality tools is indeed worth it in the long run.

High-Quality Tools are Indeed worth the Investment

When you purchase high-performance and high-quality tools, you can recalibrate, reground and recoat it to extend the life of the tool.

Here at Alok Tools, we are pioneers and leaders specializing in Industrial Tools & Supplies. Our product team uses the best quality materials for tool making, and our product engineers use the best technology like micro-finishing and more to ensure that all tools we make last for a long time to come. Our tools are designed to withstand abrasion, resistance, wear, and tear.

Get in touch with us to know more about our tool manufacturing process and to find the best tools for your specific application.

There’s no single answer to this question. You have to consider several factors like tool size, tool life, tool type, usage, application and of course, the cost before you can decide on the answer. In today’s post, we discuss the pros and cons of both these commonly used materials for tools. We also help you understand when to use which material.

General Characteristics

HSS:

High-speed steel (or HSS in short) is steel used for making tools that contain large amounts of tungsten. The general composition of HSS is – tungsten (18%), chromium (4%), vanadium (1%), carbon (0.7%) and the rest iron. HSS tools have a hardness rating of 62 to 64 Rc. By adding cobalt (5 to 8%) to HSS, you can add high strength to it and improve the resistance of the material. Typically, tools like drills use HSS with added cobalt.

Carbide:

Carbide or cemented carbide is a hard material used in the manufacture of cutting tools. Carbide is cemented together using a binder material. Titanium carbide (TiC), Tantalum Carbide (TaC) or Tungsten Carbide (WC) is used as the aggregate.

Tools made from carbide can withstand higher temperatures compared to tools made from HSS. Similarly, carbide offers superior cutting performance when compared to HSS tools.

High-Speed Steel Vs. Carbide – A Showdown

Round 1 – Cost

Generally, tools made from HSS have excellent toughness and are quite hard. Also, since HSS cutting tools are cheaper than carbide cutting tools, tools made from HSS are cheaper compared tools made from Carbide. This makes HSS tools a better choice for “high-mix, low-volume” applications.

Round 2 – Tool Life

Carbide is harder than HSS, making carbide tools have a longer life than conventional HSS tools. However, though carbide is extremely hard, it could become brittle with usage. This means the cutting edge on carbide tools are likely to chip or fracture in certain conditions.

Applications in which HSS excels over Carbide:

• A set-up that is not rigid
• The component that has to be cut or machined is poorly clamped
• Machines that have poor spindles
• The tool is a long-reach type, with an extra overhang from the tool holder

Now, that you’ve seen the two main deciding factors, let’s take a look at the common machining operations so that you get a clear picture of when to use HSS or carbide tools.

Drilling

If your application requires high-volumes of hole production, then it makes sense to invest in carbide drills, despite the initial higher cost. Carbide drills with internal coolant ducts work well for deep, high-volume holes.

Additionally, carbide drilling is the best way to produce holes faster and more efficiently in a wide range of metals, because of the higher cutting speeds that can be achieved. Sometimes the cost of investing in carbide tools can also be justified in low-volume production due to its capability to drill holes in metals with high hardness.

Now, that we’ve seen the applications where carbide drills work better, let’s turn our attention to applications that require HSS drills.

HSS drills have a wide range of applications like – short batch runs, handheld machining and more. They are tough, and the lower initial cost makes them a great choice for hand-held drilling, deep hole drilling, stack drilling, and other applications, where an internal coolant is not available.

Tapping

When it comes to tapping, HSS tools are typically the first choice. They are mostly used for internal thread production. Given their general toughness, HSS tapping tools are also used for MRO (Maintenance-Repair-Operations) industries. The most common types of taps used are straight flute taps and hand taps. HSS taps are also used in large volume applications.

Carbide tips are not used much because of the brittleness of carbide. When tapping, it tends to chip and crack. As noted above, HSS has higher toughness compared to carbide, which makes the former a better choice for tapping.

Tapping by itself is a slow speed, high feed process, and the toughness of HSS makes it a superior performer for this operation compared to carbide.

With that said, there are some specific tapping applications where carbide works better. They are:

• Tapping hardened steel at a specific geometry
• Tapping high-silicon aluminium as silicon is abrasive and carbide provides the best resistance

Milling

When it comes to milling, carbide endmills are the most used. The variable helix designs and the best MRR (Metal Removal Rates) make carbide endmills the first choice.

HSS endmills are mostly used for manual milling, less rigid set-ups, and smaller volumes. However, of late, usage of HSS in milling has significantly reduced.

Introducing another Choice, the HSS PM

High-speed steel Powder Metallurgy is a recent development and aims to overcome the cons of both Carbide and HSS. As the name implies, HSS PM is made from a powder, just like carbide. This means, HSS PM has a finer grain structure, thereby offering better hardness compared to conventional HSS, while still retaining toughness.

With HSS-PM, you can have tools that last longer than conventional steel, while being tougher than carbide. Industry experts believe that HSS-PM is the answer going forward as it offers the best of both worlds.

Final Thoughts

Ultimately, finding the right tool material – HSS, Carbide or HSS PM – depends on your application type and your operational conditions. We hope this post gives you a clear idea of the different types of materials used in making tools. We are leading carbide cutter manufacturers in India. If you have any further questions, drop in our queries to our team, and we would love to help you find the perfect for your application.