Bushings

Bushings are used for press-fitting technology with pipes and fittings in the installation of plumbing and gas systems.

Production

AFA operates in the manufacture of a vast range of bushings of varying thicknesses, diameters, coupling types and lengths.

They are manufactured with cold drawing and solubilisation treatment at 1050° with a controlled hydrogen atmosphere. This process restores the material to its initial physical state by providing physical-chemical properties such as resistance against corrosion and adaptation to all types of crimping or pinching. Upon request, markings and inspection holes are available in the line, implemented through our transfer presses.

Fields of use

Mechanical bushings are used in the thermohydraulics sector for

the installation of press-fitting connections

the assembly of hoses

In thermohydraulics, bushings are a crucial component in the installation of press-fitting systems and the assembly of hoses.

AFA produces a range of bushings, also known as pipe bushings, that fulfil the various needs of companies operating in the thermohydraulic sector, from those used to build systems, to companies who produce home appliances such as air conditioners and coolers.

For these businesses, having an excellently functional mechanical bushing has proven to be simply indispensable. AFA manufactures stainless steel bushings according to the traits that have been characteristic throughout its history since 1973: precision, quality, experience and competence.

Steel is the prime material, thanks to its chemical characteristics, as well as mechanical, which offer the highest resistance. Accordingly, even small components such as bushings are able to guarantee maximum benefits, with the overall result being near-imperceptible, yet no less noteworthy.

Mechanical bushing: all of AFA’s quality

AFA bushings for pipes are available in various sizes manufactured from owned dies, starting from a minimum diameter of 14 up to a maximum of 75. They come in various thicknesses, types of couplings and lengths.

Maximum customisation is guaranteed by the in-line markings and inspection holes, available on request by the customer and perfectly adaptable depending on the single project. They are manufactured directly in-house at the transfer presses, which are also owned.

The result is quality bushings for pipes, exclusively manufactured through cold drawing. Accordingly, the material does not feature any welding area and appears invulnerable to situations of breakage. Plus, the natural tendency to corrosion is avoided, resulting in products that are not only efficient and reliable but also long-lasting.

Special care is dedicated to the stage after moulding, during which the pipe bushings are deburred and polished. Each mechanical bushing goes through a special solubilisation treatment at 1050° in a controlled hydrogen atmosphere. This process makes it possible to enlarge grub screws and, therefore, the material at its initial physical state, preventing possible breakage from happening during pressing with the fitting and the pipe.

This achieves additional resistance to corrosion and maximum versatility of pipe bushings which are then perfectly adaptable to all types of crimping.

The added value of AFA pipe bushings

AFA bushings are characterised by high quality, versatility, and reliability. This is thanks to the considerable resistance that they feature against corrosion, guaranteed by the solubilisation treatment at 1050° in a controlled hydrogen atmosphere.

Plus, they are manufactured with forms of direct and indirect protection, in addition to offering efficiency and functionality of the entire process, in the name of respecting the environment, ranging from production in view of quality and affordability, up to the choice of sources where there are no conflicts. Products that are efficient all-round, manufactured with skill and respect for the environment.

Tolerance rings

Tolerance rings are used as friction-based retaining elements between two coupled components.

Production

AFA manufactures standard and custom, on request, peaks.

Depending on the sector of application and the specific requests, AFA manufactures tolerance rings exclusively with stainless steel. The chosen thickness depends on the specifications of the tolerance rings.

Fields of use

Tolerance rings are used in electric motors in the automotive industry as

Supports for gears

Security devices

Car doors

When we talk about tolerance rings, we are referring to special rings with radial spring that are pressed on, acting as friction clamping elements – between two coupling components. They are flexible packing elements created to keep two cylindrical parts together. Around the circumference of the tolerance ring, there are undulated protrusions that are able to generate a retention force that provides the perfect adaptation between the two components. All of this without the use of adhesives or excessive assembly force (which also simplifies the process for the manufacturers).

How to benefit from tolerance rings and how do they lower noise

Tolerance rings are also usually employed as bearing supports, in addition to the ideal means for managing torque transfer, protection against torque overload and axial gliding between coupling components. These types of products can also be used to insulate undesirable vibrations in electric motors and to streamline mechanism operation in appliances and cars. In fact these are sectors where the need to contain noise has become increasingly more important in recent years. Plus, in view of product customisation, it is also possible to make changes to tolerance rings to adjust the isolatable frequencies and the dynamic rigidity.

Automotive sector and climate control

Tolerance rings can be used to completely eliminate noise by simply occupying space between the coupling components that would otherwise lead to vibration in the system as the parts are not completely coupled.

As for the main sectors that use tolerance rings, the main one is the automotive industry. In fact, here, tolerance rings are used broadly in automobile kinematic chain and steering systems, as well as inside and outside the vehicle. They are used as friction devices in various applications, for example, in automatic tailgate door motors. In other words, the moment the boot door is lowered and a sensor detects an obstacle, the motor is signalled to stop. It is the tolerance ring that will protect both motor and gear – acting as a clutch – against excessive forces. Car manufacturers also use tolerance rings to install bearings (in hinges of the power plant as well as in the hinges).

Another context that uses these supports is climate control since tolerance rings are used in the mechanisms of air conditioning systems in both residential and industrial settings.

Brush holder

Brush holders are used to contain and direct the movement of the motor brushes and guarantee their correct operation.

Made with brass, they are compliant for the transmission of electric current and available with a hard plastic central body to guarantee insulation of the support.

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Production

AFA manufactures standard brass brush holders with a thickness of 0.5 mm and 0.8 mm. Upon request, it is possible to provide custom brush holders with a part made with unfinished or self-extinguishing plastic.

To guarantee the maximum glide of the brush during its consumption, the seat needs to be produced with the blanking burrs facing outwards.

Fields of use

The brush holders are used in small 220 V motors such as for

hair dryers

immersion blenders and blenders

coffee machines

The perfect operation of the electric motor is the result of the synchronised movement of a series of components. In this sense the role of the brushes can be defined as crucial, given that their constant movement on the windings is what generates the movement of the device. That is why the brush holders are so important: they have the task of containing and directing the movement of the brushes and are mainly responsible for their correct operation.

Tiny components but hugely important

The housings that contain the brushes can be manufactured on request and customised based on specific need, starting a production process that is distinguished by the care of great craftmanship. The brush holder for electric motors is a tiny component, yet it is fundamental to ensuring the correct operation of accessories and objects that are powered with electric current. In addition to guiding the movement, the task of the brush holder in an electric motor is to also place the brush in contact with the rotating part of the motor.

What tools use brush holders

Mostly small 220 V motors – such as those in blenders, mixers, hair dryers, and coffee machines – where it is possible to use brush holders. These are usually made with brass or ryton. Obviously, it is necessary to guarantee maximum glide of the brush during use. Besides, as for the seat, it needs to be manufactured with the blanking burrs facing outwards. Furthermore, for maximum customisation, it is also possible to request the production of brush holders assembled with self-extinguishing or unfinished plastic parts.

Electric motor and brush holder: design and manufacture

To talk about brush holders for electric motors means components that are generally tailor-manufactured with the aid of special processes such as turning, milling and wire electro erosion. Companies specialising in manufacturing mechanical hardware, such as Afa De Giorgi, produce different models of brush holders in terms of both shapes and thicknesses. Accordingly it is always possible to be certain you are using the most suitable supports for the electric motors, especially when referring to small appliances. Once the customer has requested a specific type of brush holder, the company takes over the design and manufacture of the product.

The importance of choosing the best company

In addition to brass and nylon there are special cases that use metal or flame-proof insulating materials. By availing of equipment and company staff to complete the entire process, the work shall always be monitored: accordingly competence and quality are guaranteed.

Motor covers and supports

The covers and supports for motors are crucial for reducing motor vibrations and lowering the noise level.

Production

AFA manufactures motor covers and supports made of iron with galvanising treatment. Threading is made during the moulding phase to reduce the costs stemming from manual recovery.

In addition to standard components, AFA produces motor covers and supports based on customer specifications.

Fields of use

Motor covers and supports are used in electric motors for

seat adjustment

gates

forklifts

E’ dal 1973 che la ditta Afa è presente sul mercato ed è nata – iniziando come torneria – per volontà dei fratelli Attilio e Gianfranco De Giorgi. Quello della produzione di particolari per motori elettrici e componenti per la termoidraulica è oggi il settore di punta dell’azienda. Ben presto, fin dalla sua nascita, la ditta si è occupata della costruzione dei primi rudimentali stampi per effettuare lo stampaggio a freddo.

Contacts and Faston terminals

Faston terminals are electric connectors that are normally used in the electrotechnical industry and electronics.

They are used to connect the ends of two conductors and allow electric current without the use of a mechanical connection.

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Production

AFA manufactures contacts, Faston terminals and brass, copper and phosphor bronze IDCs. Upon specific customer requests, the company intervenes with post-moulding galvanising treatments, including selective or by a pre-tinned strip.

To guarantee easy insertion and automation, AFA provides terminals wound around special cardboard reels that go through complete testing with moulding line video cameras.

Fields of use

Contacts and Faston terminals are used in very small electric motors such as

extraction hood ventilation motors

oven cooling motors

electric boards

When we talk about Faston terminals, we are referring to a special type of electric connectors with a blade that are normally used in the electrotechnical industry and electronics. They are used in a vast range of equipment; they are sturdy and affordable and can be used in many varieties. They first appeared on the market around the 1960s, and it was under the nickname they were given in the catalogues of an American company that they became popular (i.e. ‘fast on’, easy to assemble).

Types of Fastons and how they are made

There are two types of Fastons: the male faston, which has a flat and straight blade, and the female Faston, with a blade that curves at the sides to fit the male. It is also possible to make distinctions in terms of electrical insulation: there are bare, electric Fastons, where blade and connection are not insulated; partially insulated Fastons, where there is insulation only on the crimping (the cover of the connection can be shrink-wrap or rigid); insulated Fastons, with plastic shell protection (the connector is fully covered). As for the available connections, it is then possible to classify the single type of Faston, where there is only one blade, and the double Faston, which is a connector with several blades (a very common model is the female Faston with male pointing backwards). Also known as the multiple Faston, where there are several Fastons in a single container.

Materials for the production of electric Fastons

Afa De Giorgi manufactures IDC and electric Faston contacts using materials such as brass and phosphor bronze. Upon request, it is also possible to intervene with post-moulding galvanising treatments or start from a pre-tinned strip. Thanks to the video cameras installed on the moulding line, the company is able to guarantee a complete check of the moulded terminals on the reel. Since certain types of products require easy insertion and automation, the terminals can be wound on special cardboard reels.

Faston applications and when they are used

In terms of the applications for these components, it would be correct to affirm how contacts and Fastons are used in very small electric motors (for example, in extraction hood motors for ventilation but also in fridges and oven cooling motors). More generally, certain components are used in electric boards. By now, the use of Fastons is considered essential for electrical connections since it is nothing more than a connector to be added to the end of an electrical cable: the ultimate goal through it is to be able to connect it to another device or network. This termination can simply be a conductor on the end of a cable or also have other extra elements (anchoring screws, for example).

Magnet block springs

The magnet block springs, also called ferrite springs, are used to block the magnets inside the motor tube.

Production

AFA manufactures standard and custom magnet locking springs based on customer specifications.

Available in austempered C67, pre-hardened C67 and stainless steel so as not to interfere with the magnetic fields of the electric motor.

Fields of use

Ferrite springs are used, for example, in electric motors to

adjust seats in the automotive sector

actuate gates

adjust beds

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Calibrated washers

Calibrated washers, also known as packing washers, are used as shims to reduce the transmission of vibrations and compensate the axial backlash.

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Production

AFA manufactures precision and calibrated flat washers.

Available in stainless steel, brass, iron and C67, they can go through various surface galvanising treatments (deburring, polishing, evaporating oiling) that provide different physical-chemical properties.

In addition to standard components, AFA produces custom packing washers based on customer specifications.

Fields of use

Calibrated washers are used in the electric motors of

WASHING MACHINES

DRYERS

DISHWASHERS

Calibrated washers are truly essential components for easily and quickly setting and adjusting both the height and the distance between two parts. They are useful as references for boats, vehicles, machines and different types of structures, but also specifically for the operation of industrial equipment. Packing calibrated washers make it possible to transmit axial forces: they can have various diameters and measurements; furthermore, they can be produced using different types of materials and always maintaining high quality.

Wear, stress and surfaces

There is no risk of wear or deterioration: they can withstand different stresses and be used in any operating environment without any danger of slackening. Calibrated packing washers also offer great conductivity, both electric and thermal. The surface is uniform, smooth, and free of any burrs. They also guarantee, in terms of practicality, immediate and easy removal, reducing technical times, especially in terms of the operator’s work.

Calibrated washers can be used whenever industrial assemblies require minor calibrated packing. Afa De Giorgi manufactures precision flat calibrated washers and calibrated washers: they can be used successfully to limit the transmission of vibrations, but also as separating elements. The company is able to produce stainless steel, brass, iron and C67 components(later and finishing galvanising treatments can also be carried out).

How calibrated washers are made

Let us see how calibrated washers are made. Specifically, these are supporting and adaptation discs that can be used when it is necessary to intervene on specific points to compensate for axial backlash (caused by manufacturing tolerances). An example? A spindle with a safety ring. Combining the various thicknesses of the various washers could help intervene compensating this backlash.

The elements that need to be assessed for a conscientious purchase

Certain elements always need to be considered so that the purchase of a given model of packing calibrated washers is exactly the right one. The first thing is to aim for high quality; in fact, this is the only way to be sure of the long-lasting duration of the relative supports. In fact, work completed with the aid of poor quality materials offers a short service life and it is, therefore, advisable to implement this solution from the start. Naturally, one must consider the choice of materials used to manufacture the product being purchased. The same goes for the price of the components: seeking the advice of a technical team specialised in the sector, such as the team at Afa De Giorgi, means aiming for the best quality and convenience. Not least because the online portal makes it possible to focus on support types, models and prices in a very transparent way.

Bearing Retainer

Bearing retainers can be used to retain both the sintered ball (bushing) as well as the bearings, making them glide more easily.

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Production

AFA manufactures standard and, on request, custom ball locking springs.

Available in various thicknesses, diameters, and shapes, they are produced in C67 and stainless steel. C67 components always undergo austempering: a process that increases the physical properties. AFA guarantees consistency, regularity, and repeatability of dimensions and loads, which is essential in assembly processes.

Fields of use

Bearing retainers are used in the electric motors of

washing machines

dryers

dishwashers

It is important to pay extra attention to everything regarding bearing maintenance, as this directly affects performance. Both correct maintenance and the relevant handling can help extend the operational life of the supports. Downtime is minimised, and productivity is increased, resulting in huge savings. The importance of bearing retainers, therefore, becomes clear; they are components that can be used successfully for both bushing and bearing retaining.

Standard or custom supports can be manufactured

Afa De Giorgi is specifically able to provide them in C67 as well as stainless steel, ranging in various diameters, shapes, and thicknesses. Both standard and custom ball locking springs can be manufactured. Bearing retainers are normally used in the motors and drains of dryers and washing machines. It is important to guarantee the customer the maximum consistency and repeatability of the loads, especially when it is necessary to rely on a certain regularity of assemblies. All of this is made easier by the use of an in-house C67 austempering furnace.

Assembly, cleaning and correct lubrication of the component

Before proceeding with bearing assembly, it will be necessary to inspect both the housing and the shaft in search of any damage and, more in general, to analyse the physical conditions of the support. The surfaces will need to be cleaned with the aid of a soft cloth to be sure of any scratches or burrs that need to be removed. It is also crucial to lubricate the bearings with products, such as oil or grease: much depends on the environmental conditions, speed, and load in addition to temperature. Poor assembly can jeopardise the service life of the support, as would incorrect or poor lubrication or a strong overload, causing stress that is able to generate breakage.

The importance of preventing premature bearing failure

The greatest problem to face – and to prevent – is early bearing failure, a true inconvenience that factories aim to prevent during machine and equipment operation. On top of causing great losses relative to running costs, these failures can also lead to an increase in machine downtimes (and resulting slowdown of production). That is why each part must be connected with the other, and for this reason, the bearing retainer supports are integral parts of this larger design. Bearings are not all the same: it is important to choose the best shaft locking mechanism and the best seal to raise the performance level and increase the bearing’s service life.

Compensation springs

Compensation springs are used to reduce the noise and vibration levels of electric motors, increasing strength, duration, and overall performance.

Their function is to compensate for axial tolerances of the bearing, avoiding the slackening of the balls in the races as though they were shock absorbers.

Production

AFA manufactures standard and, on request, custom compensation springs.

Each shipment includes the compression test results conducted on each production batch and the spring load chart.

Standard models manufactured with C67 and hardness 45 – 50 HRC, obtained through austempering treatment with salt quenching. A procedure that provides the part with maximum elasticity, maximum fatigue strength, and uniform thrust on all of the contact points.