Circular Bellows Manufacturing Process: Material, Molding, and Testing

Molding and Forming Methods

The industrial circular bellows manufacturer uses various methods depending on materials and specifications. The forming process differs significantly between metal and elastomer versions.

1. Metal Forming Techniques

The hydroforming uses water pressure to shape metal tubes into precise patterns. This method creates uniform wall thickness throughout the entire component. The roll forming uses rollers that gradually press flat metal sheets. The edge welding joins thin metal discs at their inner and outer edges.

2. Elastomer Molding Processes

The compression molding is the pressure placement of raw rubber into a heat mold under pressure. During the curing process, the liquid mass is that which is flowing and forming at temperatures of approximately 165 °C. 

The injection processes cause liquid rubber compounds to be introduced into the cavities molds quickly. Transfer molding forces the rubber into the final molds previously shaped.

3. Finishing Operations

After the initial forming, parts require careful trimming and inspection. The flash removal eliminates excess material that is squeezed between mold sections. The surface treatments enhance corrosion resistance for metal components after annealing. 

Some flexible circular silicone bellows receive special coatings to reduce friction. These elaborations make sure that it has good operation in the tough applications.

Testing and Quality Control

Strict testing ensures components meet strict performance and safety standards. The high durability circular rubber bellows undergo multiple inspections throughout production. The testing protocols verify dimensional accuracy and functional capabilities under stress. These quality checks are there to detect defects as the products are being shipped to the customers.

1. Dimensional Verification: The fine measurements verify that there is no inner and exterior desired mismatch between inner and outer diameter. Wall thickness influences flexibility, which has to be the same everywhere. Special measuring equipment is used to test the convolution pitch uniformity by the inspectors. Any minor differences may affect the performance of vital applications.
2. Performance Evaluation: The pressure testing exposes the samples to a 1.5-fold working pressure. This verifies safety margins and identifies potential weak points. Leak detection uses helium or bubble testing methods for airtight components. The circular expansion bellows must maintain seals and accommodate movement.
3. Durability Assessment: The cycle testing replicates real use by flexing components thousands of times. The machines record exactly when and how samples eventually fail. Extreme temperatures and conditions of chemical exposure are replicated in environmental chambers. Hardness, tensile strength and elongation are confirmed by testing of materials.

The manufacturers document test results for quality assurance and certification purposes. These records provide traceability throughout the product lifecycle. These testing data are used to advance these processes of improvement. The information helps engineers refine designs for better performance.