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Manufacturing Hinges Different sets of hinges can vary in utility, efficiency, and price. One of the reasons for this variation involves the materials and processes used to create hinges, which are ever-present in day-to-day life. Although hinges have been in use for thousands of years, standardized hinge production methods did not come about until the relatively recent era of mass manufacturing and advanced machining. Despite sharing certain basic principles in design and application, modern hinge production may be considered a far more complex process than its ancient precursor.The categorization of different hinges is often dictated by the base materials, tooling, and machining techniques employed to create them. Metal is the most common material used in hinge manufacturing, and therefore metal fabrication methods form the majority of hinge production processes. While these metal fabricating procedures are also frequently used in a range of other industrial manufacturing projects, there are certain characteristics that make them unique in hinge production. Hinge Materials The forming material used for hinge production is an important factor in both the hinge’s cost and its applications. Steel is one of the most commonly employed metals due to its mechanical durability and relative versatility. Although it is an alloy of carbon and iron, steel can be further alloyed with other metals to produce compound materials. For example, mixing steel with chromium and nickel results in stainless steel, which has high rust resistance and is beneficial for hinges that will be exposed to moisture or other corrosive substances. Brass is another common hinge forming material. It is an alloy of zinc and copper, with greater malleability and a lower melting point than either of its base metals. The relative ease of fabricating brass, as well as its yellowish-gold hue, make it popular for designing hinges with decorative applications. Similarly, bronze—an alloy of tin and copper—is comparatively easy to form and provides a reddish surface color for aesthetic value. In addition, bronze has a low metal-to-metal friction level, making it well-suited for a hinge’s joint functions. Hinge Production Processes Manufacturing hinges is a value-added process, so a hinge’s cost often depends on the length and efficiency of the production methods used to create it. Generally, hinge production usually involves some amount of thermal treatment. The forming material is first heated in an industrial oven or smelting unit in order to make it more malleable. Heating or even melting the metal stock makes it much easier to shape into different configurations and can also alter its chemical composition. The next step involves machining processes that either stamp, cut, flatten, or deform the workpiece into a serviceable hinge component. Casting is one of the more common machining techniques used in hinge production. In this process, metal is first melted and then forced through a mold that allows it to solidify into the desired shape. After casting, finishing treatments, such as smoothing or polishing, are applied to enhance the aesthetic qualities of the hinge part. Hand-casting and similarly labor-intensive variations tend to elevate the price of the hinge. Some other common categories of hinge machining methods include: • Extrusion: This technique uses high pressurized force to compress the metal workpiece against a specially-shaped die. Extruded hinges tend to be stronger and thicker than stamped hinges, but are produced at a higher cost. • Deformation: Deforming the metal into a hinge shape can involve bending, spinning, rolling, or forging it. Drawing and deep drawing elongate the metal, stretching it until it attains a desired form, while turret punching uses a sequence of dies that press against the workpiece to change its dimensions. • Cutting: Removing excess material from the metal workpiece is another way to shape it into a hinge component. This can be accomplished through sawing, shearing, drilling, or more sophisticated methods, such as laser and waterjet cutting. Secondary Processes After the main stages of production are complete, there are numerous secondary and peripheral treatments that can be used to help with hinge wear or deterioration. For example, every time a hinge is used a small percentage of its metal is worn away, so some manufacturers opt for assembling hinge components with ball bearings between each joint. These ball bearings allow a smoother glide when the hinge is in motion, and they are a valuable addition to heavier doors or bulky hatches. For aesthetic considerations, finishing treatments such as painting, burnishing, polishing, or smoothing can increase a hinge’s decorative appeal, while rust-proofing can help ensure the hinge will have a longer and more efficient life as an integral component.
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