Brass components manufacturing from brass Bars

Everyday we come across many object in our routine. Those objects are made from plastics, metals, earth matters, alloys or combination of multiple types of materials. We can observer many brass metal components in those objects. Brass is not a pure metal but it is an alloy metal of copper, zinc and lead. Brass metal components are found in electrical accessories, home appliances and may other machineries. But do we know how those components are manufactured..? Let's try to understand the making process of those brass components from brass Bars.

There are thousands of factories manufacturing brass components from brass metal bars. Jamnagar City of Gujarat (India) is the biggest hub of brass parts manufacturing companies. All types of brass components manufacturers may have different manufacturing processes. But all of them follow some basic steps for manufacturing of brass components.

In this article we will skip details manufacturing of Copper, Zinc or Lead metals from their Ores. We know that Brass is not a base metal but an alloy made from Copper, Zinc and Lead metals. So we will focus on manufacturing process of Brass components from the brass metal bars. The entire process includes below processes.

1) Melting Brass Metal.

2) Molding Brass metal into Brass Bullets

3) Preparing Brass Bars from Brass Bullets

4) Cutting the Brass Bars into semi-furnished Products

5) Finishing Brass Components

6) Quality Testing and Packing

Casting Brass Metal :

Brass metal scrap or mixture of Copper, Zinc and Lead are placed in appropriate crucibles and heated till the metal turns into liquid melt. The heating can be done through conventional coal based furnaces or electrical furnaces. Selection of crucible and furnaces are very important for economic, energy efficient and homogenous melt.

Molding Brass metal into Brass Bullets

Once the brass metal is melted into a homogeneous liquid, the crucible is taken out of the furnace. The melt is poured into bullet shaped casting molds followed by cooling process. This process turns the brass melt into larger size brass bullets.

Preparing Brass Bars from Brass Bullets

Brass bullets are heated again and pushed through dies to form brass bars. Those bars are not straight and semi furnished. Those bars are further processed for finishing. Those bars are also straightened for machining.

Cutting the Brass Bars into semi-furnished Products

The brass rods then are sent for machining and semi-furnished products or components are produced by machining process.

Finishing Brass Components

Then the semi-furnished products are taken for different re-machining operations like drilling, threads etc and converted into final product or component of final product.

The final products or components are then sent for surface finishing processes like polishing or electroplating. The surface finishing is not necessary for every product or components.

Quality Testing and Packing

Now the product or components are ready. But these items go through Quality testing before moving to warehouse for shipping. The QC methods could be manual, semi automatic or fully automatic process depending on the accuracy level requirements.