Saturday, December 16, 2006

CNC punch press choice based on experience

A generous specification for a cost-effective price and a short delivery time led to the choice of another CNC punch press by a switchgear manufacturer, based on past experience.

Howarth Switchgear has built its business on providing exactly what customers want when they want it, and to give it the capacity and flexibility to meet these demands it has just invested in a new LVD Parma 1212 CNC punch press. Director Chris Howarth says that the key arguments for the Parma were that it gave a generous specification for a cost-effective price and a short delivery time. He was also convinced it would be reliable, as the company had been running a punch press from LVD's predecessor Shape Machines for the past twenty years with very few problems - and those problems that did occur were fixed very quickly.

'The Shape machine has worked well for us with very few breakdowns, but we thought it was time to move on,' he said.

Howarth's business is building electrical switchgear systems for all kinds of non-domestic premises - from banks and call centres to chemical plants, food processors and military installations.

And even though they try and incorporate standard elements, no two systems are the same.

'Every building is different and the system requirements in buildings are changing all the time,' said Howarth.

'If you are refurbishing a building you are going to need 100 to 150% more power because everything now is IT-oriented.

And if you have more computers you need more air conditioning to deal with the heat they give out.

The result is that they end up trying to get much more switchgear into the same space as they used before.

So it all has to be specially built.

The other problem is that sometimes the switchgear may be in a basement or on a roof and you have to design it in sections so that you can get it through the existing services.' Co-director Anthony Howarth added, 'Because we have a bespoke product we feel we have to do all of our own sheet metal.

Although systems may look similar there are always small differences that would make it very difficult for someone working with standard cut parts or bought-in frameworks.

If we relied on anyone else's casework we wouldn't be flexible - we give the customer what they want rather than what someone else stocks.' As well as this flexibility, the other factor that allows Howarth Switchgear to offer a premium service is its speed of delivery - and again, the only way to ensure that is to manufacture the critical components in house.

'We are mass producing one-offs, but that is what you have to do.

The Parma might seem quite a big machine for what we do, but the way we see it is that if you can do what the customer wants and react more quickly you will get more work in.

Because we can deliver on time with what the customer wants, they will be able to get the plant up and running sooner.' The LVD Parma punch press offers the speed and flexibility of programming and production that Howarth Switchgear needs.

With a 21-station turret including three direct-drive 50.8mm auto-index stations it gives a wide range of options with a standard tooling setup - and it needs it as Howarth designs and makes around 250 new parts every month.

The Parma 1212 features GE Fanuc 0iP CNC control, and rugged frame and table design to achieve tight tolerances and consistent punching accuracy.

LVD says that it can deliver up to 300 hits/min on 25.4mm centres, and nibble at up to 650 hits/min with a finished part accuracy of +/-0.1mm and +/-0.05mm finished part repeatability.

As Anthony Howarth explained, 'Auto-indexing isn't new technology but it will offer a lot more possibilities, and the programming is much more flexible and faster.

We aren't stubborn and are very prepared to grow into the capabilities of the machine and the software.

One of the things I liked about the Parma was that the punch press and the software came as a package, and the Cadman P 3D software has an unfolding module so that you can flat pack your parts from a 3D file.' The speed and quality of the manufacturing process is extremely important to Howarth's work and cash flow, said Chris Howarth.

'These can be really large installations and a considerable amount of cash (in components) can be tied up on the shop floor.

What we were looking for with the Parma was performance and flexibility at a cost effective price and we are now applying the Parma's advanced technology to speed up our work flow which in turn can only benefit our customers.'

CNC laser cutter/profiler runs unattended

A UK automotive and aerospace sheet metalworking subcontractor has selected a high speed CNC laser cutting machine with automatic storage/handling to increase production capacity.

A Prima high speed Platino laser cutting machine, complete with 10-storey automatic work handling system, has been selected by automotive and aerospace sheet metalworking specialist PAB Coventry, UK, to increase its manufacturing capacity for high precision profiled parts. Capable of achieving cutting speeds of 140m/min and head acceleration of 12m/s2, the new Prima machine has a 3m x 1.5m bed and is equipped with a 4kW laser suitable for cutting mild steel components up to 25mm thick. 'As a Tier 1 supplier to leading automotive OEMs including Aston Martin, Jaguar and Land-Rover, high accuracy with fast throughput are key requirements for us,' said PAB's laser systems manager, John Laud.

'The new Prima machine supersedes an existing laser profiler and andshy; thanks to its automated work handling system andshy; enables us to run jobs unattended right through the night if needed.' He added: 'The Platino machine both fully supports our multi-shift manufacturing operations and provides significant cycle time reductions across the 500 different laser cut components we currently produce on site.' The new machine's high dynamics are backed by exceptional precision, enabling it to achieve positional accuracy of 0.03mm across its entire work area, along with a repeatability of 0.03mm.

This is achieved through a fixed workpiece design and the use of advanced flying optics.

The Platino's productivity and performance are also enhanced by its off-line programming capabilities, optional nesting software and in-built anti-collision safety device.

Further features include simple installation, automatic and programmable control of the equipmentandsup1;s focal position and rapid lens changes, enabling instant switching between material types and a wide variety of sheet thicknesses, without adjustment.

PAB's selected 10-storey tower server is one of a series of work handling options for the Platino machine, which include automatic pallet changers, sheet loaders and flexible loading and storage units.

* About Prima Industrie UK - Coventry-based Prima Industrie UK draws on the established track record of its Italian parent organisation, Prima Industrie, a world leader in the design, development and manufacture of laser cutting machines and automation solutions.

Prima UK provides sales, installation and servicing for a wide range of new and pre-owned 2D and 3D cutting machines that are used by customers in industries as diverse as aerospace, automotive, marine and electrical equipment manufacture.

Friday, December 15, 2006

Debris shields reduce high power laser costs

Debris shields protect high precision final reflective or refractive focusing optics in high power lasers and cost effectively extend their lifetime.

Debris shields reduce high power laser costs Debris shields protect high precision final reflective or refractive focusing optics in high power lasers and cost effectively extend their lifetime. Optical Surfaces, specialists in large and high precision optics, have considerable expertise in the manufacture and supply of debris shields to protect the target-facing optics of large high-power laser facilities. As large laser facilities increase in beam energy and target size, the likelihood of producing shrapnel and debris that may impact and degrade target-facing optics lifetimes also increases.

The use of debris shields to protect these high precision final reflective or refractive focusing optics is a well-established technique of cost effectively extending their lifetime.

Working with a range of glasses including BK-7 and fused silica, which offer good homogeneity and transmission from the UV to the Near-IR, Optical Surfaces.

is today a leading supplier of large debris shields for high-power lasers.

Manufacturing large, high quality debris shields combines the dual demands of producing a precision wavefront on a flexible window with a high diameter to thickness ratio.

Benefiting from a stable manufacturing environment and proprietary production techniques Optical Surfaces' skilled and experienced craftsmen are able to economically produce debris shields of diameter (75-400mm) and thickness (2-15mm) with typical wavefront error of lambda/10 and surface finish of 40/20-10/5.

Optical Surfaces ISO 9001-2000 approved manufacturing facility provides the flexible resources to supply from single specialist requirements to OEM quantities.

All high-power laser debris shields are provided with a complete quality test assurance report.

CNC plasma-arc machine brings work in-house

Specialist steel plate supplier now has a high-quality CNC plasma-arc profiling system that has improved its production efficiency and reduced its reliance on external suppliers.

IMS (International Metal Service) UK's Birmingham facility specialises in the supply of abrasion-resistant and high-yield, high-strength steel plate and profiles. By investing in an ESAB Suprarex SXE-P 4000 machine with a high-quality plasma-arc system and ESAB Vision 55 CNC controller, the company has improved its production efficiency and reduced its reliance on external suppliers for laser-cut components. To maximise the machine's versatility, as well as the precision plasma head, it also has a Cooljet gas cutting torch that cuts faster than conventional gas cutters and has an extended nozzle life.

The plasma head cuts with near-laser quality, producing high-definition components from plates up to 25mm thick (30mm can be cut if the finish is less critical).

Unusually, IMS specified twin fume extraction cutting tables instead of the normal double-ended single table that allows loading/unloading at one end while the machine is cutting at the other end.

The reason for this is that, by having separate tables, there is no risk of the cutting process being disturbed by items being lifted on or off the non-cutting side of the machine.

With the configuration that IMS has in place, the Suprarex can cut plates up to 6m long by 2.5m wide.

All fumes are filtered via a filter unit rather than being vented to atmosphere.

ESAB's Vision 55 Windows XP-based CNC controller is equipped with a cutting and marking database with automatic parameter setting that helps to save time and eliminate the risk of errors being made when each job is being set up.

Furthermore, the ESAB Columbus software enables clearance holes to be produced with virtually no witness marks at the start/finish position.

This is because the Columbus package automatically ramps down the voltage after the cutting head has described a 356 deg arc, enabling the hole to be completed to an exceptionally high standard.

Where countersunk and counterbored holes are required, the plasma torch is used to mark the centres so that these can be drilled with no need to carry out any additional measuring or marking.

Many of the components cut by IMS are also plasma-marked with the customer's name and/or a part number or other information.

Compared with the conventional plasma cutting machine that IMS previously used, the new Suprarex is capable of producing a far better quality of cut as well as improving the production efficiency.

In addition, the machine can cut thinner material, whereas IMS previously had to sub-contract such profiling to a firm with a laser cutting machine.

Adrian Hance, the divisional director, commented: 'The Suprarex machine was definitely worth the investment'.

'Customers appreciate the improved quality that is now available, and the machine will increase the volume of work we can handle.' He was also very pleased with the level of service received from ESAB: 'If ever we need anything, ESAB always responds quickly and gets a service engineer on site very rapidly.

Thursday, December 14, 2006

Disc lasers cut glass with zero kerf width

Multiple laser beam absorption technology and a reflector system allow a laser beam to pass several times through glass, so cutting in one step giving 'zero kerf width'.

H2B Photonics - the laser company for glass processing - and the laser producer Rofin presented new technology for cutting glass with disc lasers at the recent Glasstec 2006 show. * The MLBA cutting technology for flat glass - the patented MLBA (Multiple Laser Beam Absorption) technology features volume absorption of the laser radiation in the glass, and not surface absorption as with commonly used CO2 laser radiation. The specially developed reflector system allows the laser beam to pass several times through the glass.

In this way, laser energy is optimally used to cut glass with a thermally induced tension fissure in one single step - 'zero kerf width' cutting.

The customer's benefit is obvious: the MLBA technology cuts single glass plates 0.2mm to 24mm thick, or even multi-layer glasses (display glass, laminated glass) in one single operational step.

The usual subsequent breaking is no longer necessary and the customer can benefit from shorter production times by up to 50%.

A worldwide unique technology is the selective separation of single glass plates in a glass stack, as well as cutting of contours in one single step, which opens up completely new possibilities in glass processing.

The MLBA technology is clean and contact-free and in this way does not cause any pollution by additives (like cooling medial, cutting oil) or glass splinters.

These features make the MLBA method ideal for processing sensitive glass products or deployment in sensitive production environments.

The high edge quality, free of any glass chips or micro cracks, enhances the stability of glass parts by a factor of two.

Production losses by glass breakage or mechanical damage of high-quality glass parts are reduced to a minimum.

* Tubocut: cutting of tubular glass - the Tubocut method uses YAG lasers to cut tubular glass and hollow glass efficiently and free of glass chips.

The particular setting of laser beam and workpiece allows to exploit the energy efficiently and produces edges with the same high quality as with the MLBA process.

This reduces waste considerably during subsequent thermal operations and provides the customer with high processing stability.

* Opening up new possibilities for applications with disc lasers - as for other applications, disc lasers are most beneficial for cutting glass.

Performance stability, scalability and excellent dynamic features of the Rofin DS series with a power range of 750 to 3000W allow flexible and high-performance solutions for a wide range of applications.

YAG lasers allow the use of optical fibers, making the laser a very flexible tool, which can be integrated in almost any production environment.

By coupling several fibers to one laser, highly efficient and individual production solutions can be realized, putting the investment for laser sources in relation to the cutting system into new perspectives Present developments of the MLBA technology together with the new generation of disc lasers by ROFIN, broaden the range of applications even to borosilicate glasses achieving clearly enhanced cutting speeds.

* Products for customized solutions - H2B Photonics develops individual customized cutting solutions with the MLBA technology.

The portfolio comprises the reflectors and laser cutting heads which can be individually equipped for the process and the customer's product requirements and can also easily be integrated into existing production lines.

H2B realizes customized cutting solutions which are equipped with the requisite MLBA cutting technology and can be offered as complete systems.

For further requirements in process control, H2B offers integrated temperature measuring equipment and sensors providing additional options for complex cutting tasks.

Specialists from H2B Photonics together with Rofin experts install machines and process technology at the customer's site.

According to the customer's wishes, personnel can be trained and consulted at the H2B Photonics application center in Garbsen near Hanover, Germany, or at the customer's site.

Only high power industrial lasers by the partner company Rofin are used for system solutions.

Device pre-drills before waterjet cutting

Pneumatic device, mounted next to a waterjet cutting head, drills through awkward materials at a specific offset, then the waterjet cut is started inside the pre-drilled hole.

Waterjet cutting can be a valuable tool to many fabricators, but there are certain materials that have always proven difficult to work with. Some materials such as laminated shim stock, certain laminated composites and phenolics, may de-laminate during the waterjet piercing process. WARDJet's Pneumatic Drill allows a hole to automatically be drilled through the material at a specific offset from the waterjet cutting head.

Once the hole is drilled, the waterjet will then start the cut inside the pre-drilled hole.

The CAD/CAM program, IGEMS, can automate this entire process.

In order to use this tool an air compressor capable of 25ft3/min at 90 lb/in2 must be provided.

This will allow these materials to be cut regardless of any necessary holes.

This unique drill feature also comes in useful when cutting high tolerance holes in various steel and stainless steel materials.

By using the reaming capabilities, a customer can pierce the initial hole with the waterjet and then come back and ream it out to get the higher tolerances that are required.

This can be substantially faster then using a waterjet alone to create these higher accuracy holes.

The pneumatic drill feature is available to be mounted on any WARDJet waterjet cutting system.

This is just one of many unique features that WARDJet offers to allow their waterjet to be used in a variety of applications.

If you have a difficult application give WARDJet a call and see what they can offer as they work with you and your team to find the best solution possible.

Wednesday, December 13, 2006

Laser system cuts flat sheet and tube

A combined, automated, CNC system for laser cutting of tube and flat steel sheet takes less than three minutes to change automatically from the tube to flat steel sheet machining.

It takes less than three minutes to change automatically from the tube machining configuration to flat steel sheet machining - and vice versa - when operating the new Adige LT Combo now available from BLM Group UK. The savings that result from installing this computer-controlled combination laser cutting system are considerable, making it cost-competitive with the alternative of traditional multi-machine operations. The LT Combo is of modular design, which means the system can be configured to suit individual requirements in terms of floor space, machining capacity and the degree of automation involved.

Automation levels range up to the integration of multi-column pallet warehousing for unmanned machining.

The maximum sheet size that can be machined on the LT Combo is 3000mm by 8000mm, while maximum tube section sizes of 225mm (round), 160mm by 160mm (square) and 200mm by 100mm (rectangular) can be machined along a maximum length of 6500mm.

An integral database with a complete range of cutting parameters guarantees repeatability of cutting quality, with the machine control generating the optimum working parameters (cutting power and speed) at any point in the machining cycle.

Machining of flat sheet is completed to a positioning accuracy of 0.05mm and a positioning repeatability of 0.03mm, while 3D design and programming of tubular components and complex tubular structures (frames) is made simple with Adige CAD/CAM Tubework and Assembler software.

Machining programs can be completed in minutes rather than hours, drastically reducing the time and cost of translating a completed design into a prototype or a full-scale production component.

And the end result in either case is improved product quality, especially when the opportunity is taken to re-engineer existing designs of sheet/tubular structures to gain the maximum benefit from the dimensional and profiling accuracy of the LT Combo laser cutting system.

Nitrogen generator reduces laser cutting cost

A nitrogen generator can produce nitrogen for around GBP 0.05/m3, making it cost effective to widen the range of parts laser cut using it as an assist gas.

Considering that nitrogen makes up 78% of the air we breathe, it can come as a shock to laser users that purchasing the gas may account for 66% of their hourly running costs, according to Manufacturing Service Solutions (MSS), a specialist in laser cutting technology. With the aim of offering dramatic reductions in the cost and inconvenience of purchased gas, the company has reached an agreement with domnick hunter for the exclusive distribution of its range of nitrogen generation equipment for laser cutting applications in the UK. The partnership between domnick hunter, which has ten manufacturing plants and 25 trading subsidiaries worldwide, and MSS, which has been offering Nitrogen Generation equipment for several years, has been highly valued by customers.

In the first nine months of 2006, MSS has installed 12 systems in the UK, double its total target for 2005, by combining domnick hunter's extensive knowledge of gas generation with its skill and experience in the laser cutting industry.

For companies cutting stainless steel, thinner carbon steel and aluminium alloys, using nitrogen as the assist gas is a well proven technology, avoiding problems such as dross formation and oxidation of the cut edge.

The trend towards higher power lasers, necessary for cutting with nitrogen, has increased gas consumption, and until recently the choice for consumers has principally been between manifold cylinder packs and bulk storage, a decision fuelled by concerns over gas pressure and purity.

The nitrogen generators, supplied by MSS, filter nitrogen from the air, and compress it at 42 bar into either a bulk storage tank, or a manifold cylinder pack, giving a flow rate which is sufficient to run up to three laser machines simultaneously.

Graham Ackerman, managing director of Bridport based Ackerman Engineering said, 'We were on a fortnightly gas delivery schedule and if we ran out early we incurred high costs due to machine downtime and charges for rearranged delivery'.

'With in-house nitrogen generation we are able to achieve continuous use of our 4.4kW Bystronic Byspeed.

Additionally, it is now economic for us to use nitrogen on more jobs, which produces a much better edge quality, cuts down on edge cleaning for subsequent welding or painting operations, and results in happier customers.' Generated gas purity with nitrogen generation can be up to 99.995%.

However, these purity levels are unnecessary for the majority of applications.

Investigations have shown that using low purity levels of 99.95% on 3mm stainless steel will produce an edge quality indistinguishable from one, cut using bottled gas.

Similarly, raising purity levels to 99.99% will produce the same results for 6mm stainless steel.

Martin Cook, Director at Cutting Technologies commented, 'Prior to purchase of our ErreDue Nitrogen Generator, also supplied by MSS, we carried out tests with our customers, and they were happy with the edge quality for generator settings below 150ppm oxygen.

We run at 90ppm and achieve flow rates of over 70Nm3/hour from our generator.

Since its installation in November 2005 it has supplied our two laser machines with no 'gas outs' or breakdowns and we have never had to supplement the supply with bottled gas.' Payback on the investment was an important factor for Border Precision.

John Roche, sheet metal manufacturing engineer said, 'We were changing nitrogen packs three or four times per week.

The Nitrogen Generator has reduced the downtime caused by waiting for packs, and we now never run out of gas during the night shift.

With one laser machine our payback was less than three years, now that we have a second the payback is even shorter.' The domnick hunter generators supplied by MSS are fully expandable.

If the customer adds extra laser machines, gas generation can be increased by simply adding further Maxigas banks.

Roche added, 'The modular gas generation unit was an important factor, ensuring that the system would be able to grow alongside our requirements.' Carlos Gonzalez-Lee, managing director of MSS concluded, 'A nitrogen generator can produce nitrogen for around GBP 0.05/m3, making it cost effective to widen the range of parts cut using it as an assist gas.

Not only does this result in faster cutting times and lower gas costs, but it also produces higher quality parts, increasing our customer's competitive edge.' * About Manufacturing Service Solutions - based in Rugby, Warwickshire, UK, MSS is a privately owned company formed in 2003 by Gonzalez-Lee.

His research and experience in laser cutting, and the absence of an independent specialist laser company in the UK, provided the springboard for the company's growth.

Its core business is servicing and sales of all types of refurbished laser cutting machines.

Tuesday, December 12, 2006

Waterjet, robotic systems, spindle technology

Due to the recent acquisitions of RPT and H2O Jet, as well as the new joint-venture KMT Spindle Technology, KMT has introduced a new organisation based on four Business Areas.

Due to the recent acquisitions of RPT and H2O Jet, as well as the new joint-venture KMT Spindle Technology, KMT has introduced a new organisation based on four Business Areas.

In connection with the new organisation, KMT also presents a new management structur KMT will be organised in four Business Areas as follows: KMT Waterjet, includes: - KMT Waterjet Systems, Baxter Springs, USA - KMT Aqua-Dyne, Houston, USA - KMT McCartney, Baxter Springs, USA - KMT H2O, Olympia, USA KMT Precision Grinding, includes: - KMT UVA, Bromma, Sweden - KMT Lidkandouml;ping, Lidkandouml;ping, Sweden - KMT NanoGrinder, Lidkandouml;ping, Sweden - KMT LMV, Lidkandouml;ping, Sweden - KMT Spindle Technology, Wafangdian, China KMT Robotic Systems, includes: - KMT RPT, Auburn Hills, USA - KMT Cutting Systems, Ronneby, Sweden KMT Sheet Metal Working, includes: - KMT Ursviken, Ursviken, Sweden - KMT Herber, Vandauml;rnamo, Sweden In connection with this change, KMT introduces a new Group Management consisting of: Lars Bergstrandouml;m, Chief Executive Officer Joakim Roslund, Chief Financial Officer Per-Olof Jungqvist, Technical Director Duane Johnson, President Business Area KMT Waterjet Kevin McManus, President Business Area KMT Robotic Systems Johan Westberg, President Business Area KMT Precision Grinding Lars Bergstrandouml;m (CEO), President Business Area KMT Sheet Metal Working.

Water jet cutting expands its applications

A southern UK company reports on the remarkable take-up of water jet cutting in the architectural, building and ceramics industries and, latterly, artists.

A south-of-England company shows just how easy it can be to use a top waterjet profiler for an exciting and apparently unlimited range of applications. When first launched, many in the manufacturing industry thought waterjet technology would be largely used as an alternative to laser and plasma cutting devices in the sheet metal field. Its ability to cut cleanly through thick slabs of marble and granite were thought of as some sort of interesting spin-off.

What may come as a surprise to traditionalists is the remarkable take-up of the process by those in the architectural, building and ceramics industries and, more recently, even by those with very clear artistic ambitions.

* Enterprising expansion - charged with the task of installing a highly-individual surround to the luxury swimming pool at the multi-million pound residence of a world-renowned football club owner, the hard-working tiler involved found himself having to source a means of cutting grills into the stonework.

Having seen an existing Water Jet Sweden user in the North of England and the ease with which the cutting contract was fulfilled, the tiler was convinced that he was on to something with huge potential and persuaded his business partner, who also happened to be his father, that the purchase of one such machine could revolutionise their own local tile distribution and contracting business.

Waterjet machines such as those supplied by WJS do not, by UK sales manager Chris Baker's own admission, come cheap, but so totally convinced was the customer that he had 'seen the future', he was prepared to mortgage his own home to grasp the opportunity he visualised.

* Ingenious uses already featured on national television - installed earlier this year, the WJS 3015EB has now been featured on national television on the 'National Geographic Channel' in their programme 'What You Didn't Know About Water'.

Already the new installation is pulling in business from an astonishingly wide customer base, including applications that might seem bizarre to those more accustomed to its hitherto industrial applications.

Who would have thought, for example, that the self-same equipment that might be totally at home profiling marble friezes for the St Paul's cathedral refurbishment, in London, and granite slabs, would be called upon to produce individually designed leather fashion belts that look like lace - or would even be hired out by the hour for the production of fashionable jewelry accessories to design students?

Peter, the younger of the partnership, says that he considered several makes of waterjet profilers but, as somebody with absolutely no experience of such equipment, good support would be absolutely vital.

After meeting with Baker, managing director of Water Jet Sweden UK, and visiting the Swedish manufacturer's factory, he was in no doubt that it had to be a WJS machine or nothing.

* Standard model - the machine chosen, a standard 3.0 x 1.5m cutting size, has twin heads for flexibility, enabling it to cut two identical parts at a time or, as some users tend to do, leave one head for use for water-only cutting and the other for abrasive cutting.

It was found that a 0.2mm orifice for the former and a 0.7mm orifice for abrasive works were ideal.

There seem to be no 'typical' applications here but probably the most frequent tasks are the profiling of artistic patterns in ceramic tiles for architectural, domestic or commercial building work and, in this connection, the distinction between commercial products and art is becoming quite blurred.

It would not be too much of an exaggeration to say that the waterjet cutting process is capable of bringing art into the homes and lives of people who might never otherwise have the pleasure of enjoying it in their daily lives.

The fact that this success can be profitably achieved by someone having no previous experience, and on a perfectly standard machine, says a lot both for the WJS 3015 and its user.

Probably the two key factors in all of this are the customer's own open-minded approach and the choice by WJS of using a Fanuc 18i-MB CNC computer control system to operate the machine.

* One week training course in Sweden - the one-week course offered by WJS in Sweden as part of its sales package, rapidly enabling learning how to use the programs involved, particularly the GEMS R5 that enables drawn shapes to be entered into the system, get the user off to a great start: 'Programming is easy!' says the user but the way he has introduced so many fascinating designs is probably as much a testimony to his own abilities as it is to the system itself.

After all, other companies may require operators to have a clutch of 'qualifications' before letting them loose on such a high-value piece of production machinery.

* Stunning effect - a couple of highly-stylized 'designer chairs' are examples of new, imaginative entreprise having been assembled from 25mm-thick plywood profiles.

It is worth mentioning that, when producing shapes such as these, the 'nesting' facility within the CNC program can be used to ensure the maximum yield from the sheets of material provided, thereby holding down costs.

Other examples include ceramic motifs using contrasting colours that are then inlaid to one another to stunning effect.

* Industrial applications - this installation is just as much at home providing a cutting service for industry.

As an alternative to EDM, laser and plasma cutting, or even machining, parts such as cycle chain wheels in steel, large stainless steel washers, and many engineering components in materials ranging from aluminium to zinc, including carbon fibre, are handled.

An ability to leave as little as a 1mm wide piece of material in thick sheet is another advantage to industrial users as has been the ability to meet whatever degree of accuracy (0.3mm) that has been asked for so far.

Shop fitting and display sectors call for the use of plastic materials, while glass profiling requests are just as likely to come from heavy industry, such as automotive, as from designers of giftware for top retailers.

Said the user: 'The applications are only limited by your imagination.' In truth, after years spent on his knees tiling and then suffering physically as a result, he is now flying free and looks forward to every new day to see what exciting challenge it might bring.

* Television appearance - a recent pleasant surprise was to be featured on an edition of the National Geographical TV channel's 'I didn't know that!' program.

Last word goes to Baker who has sold waterjet machines to many UK users.

'I have always been aware of the broad markets open to this technology, but it is always a pleasure helping open-minded customers like this to get the most out of their investment and I never cease to be surprised at the things they achieve'.

Monday, December 11, 2006

Nitrogen generator reduces laser cutting cost

A nitrogen generator can produce nitrogen for around GBP 0.05/m3, making it cost effective to widen the range of parts laser cut using it as an assist gas.

Considering that nitrogen makes up 78% of the air we breathe, it can come as a shock to laser users that purchasing the gas may account for 66% of their hourly running costs, according to Manufacturing Service Solutions (MSS), a specialist in laser cutting technology. With the aim of offering dramatic reductions in the cost and inconvenience of purchased gas, the company has reached an agreement with domnick hunter for the exclusive distribution of its range of nitrogen generation equipment for laser cutting applications in the UK. The partnership between domnick hunter, which has ten manufacturing plants and 25 trading subsidiaries worldwide, and MSS, which has been offering Nitrogen Generation equipment for several years, has been highly valued by customers.

In the first nine months of 2006, MSS has installed 12 systems in the UK, double its total target for 2005, by combining domnick hunter's extensive knowledge of gas generation with its skill and experience in the laser cutting industry.

For companies cutting stainless steel, thinner carbon steel and aluminium alloys, using nitrogen as the assist gas is a well proven technology, avoiding problems such as dross formation and oxidation of the cut edge.

The trend towards higher power lasers, necessary for cutting with nitrogen, has increased gas consumption, and until recently the choice for consumers has principally been between manifold cylinder packs and bulk storage, a decision fuelled by concerns over gas pressure and purity.

The nitrogen generators, supplied by MSS, filter nitrogen from the air, and compress it at 42 bar into either a bulk storage tank, or a manifold cylinder pack, giving a flow rate which is sufficient to run up to three laser machines simultaneously.

Graham Ackerman, managing director of Bridport based Ackerman Engineering said, 'We were on a fortnightly gas delivery schedule and if we ran out early we incurred high costs due to machine downtime and charges for rearranged delivery'.

'With in-house nitrogen generation we are able to achieve continuous use of our 4.4kW Bystronic Byspeed.

Additionally, it is now economic for us to use nitrogen on more jobs, which produces a much better edge quality, cuts down on edge cleaning for subsequent welding or painting operations, and results in happier customers.' Generated gas purity with nitrogen generation can be up to 99.995%.

However, these purity levels are unnecessary for the majority of applications.

Investigations have shown that using low purity levels of 99.95% on 3mm stainless steel will produce an edge quality indistinguishable from one, cut using bottled gas.

Similarly, raising purity levels to 99.99% will produce the same results for 6mm stainless steel.

Martin Cook, Director at Cutting Technologies commented, 'Prior to purchase of our ErreDue Nitrogen Generator, also supplied by MSS, we carried out tests with our customers, and they were happy with the edge quality for generator settings below 150ppm oxygen.

We run at 90ppm and achieve flow rates of over 70Nm3/hour from our generator.

Since its installation in November 2005 it has supplied our two laser machines with no 'gas outs' or breakdowns and we have never had to supplement the supply with bottled gas.' Payback on the investment was an important factor for Border Precision.

John Roche, sheet metal manufacturing engineer said, 'We were changing nitrogen packs three or four times per week.

The Nitrogen Generator has reduced the downtime caused by waiting for packs, and we now never run out of gas during the night shift.

With one laser machine our payback was less than three years, now that we have a second the payback is even shorter.' The domnick hunter generators supplied by MSS are fully expandable.

If the customer adds extra laser machines, gas generation can be increased by simply adding further Maxigas banks.

Roche added, 'The modular gas generation unit was an important factor, ensuring that the system would be able to grow alongside our requirements.' Carlos Gonzalez-Lee, managing director of MSS concluded, 'A nitrogen generator can produce nitrogen for around GBP 0.05/m3, making it cost effective to widen the range of parts cut using it as an assist gas.

Not only does this result in faster cutting times and lower gas costs, but it also produces higher quality parts, increasing our customer's competitive edge.' * About Manufacturing Service Solutions - based in Rugby, Warwickshire, UK, MSS is a privately owned company formed in 2003 by Gonzalez-Lee.

His research and experience in laser cutting, and the absence of an independent specialist laser company in the UK, provided the springboard for the company's growth.

Its core business is servicing and sales of all types of refurbished laser cutting machines.

Partnerships across Europe provide a source of second user laser machines which are refurbished and quality checked to a high standard, enabling it to offer the exact machine make and model to suit its customers requirements.

Laser machinist acquires precision parts maker

LSA Laser Services and Automation has acquired Oeuvre Technology, a closely held precision parts manufacturer located in Plymouth, Minnesota.

LSA Laser Services and Automation announced today the completion of the acquisition of Oeuvre Technology, a closely held precision parts manufacturer located in Plymouth, Minnesota. Oeuvre Technology, established in 1994, specializes in laser cutting and micro welding of precision metal components for the medical and electronics industry. Oeuvre's capabilities include welding of round wire as small as.002 in./dia., and welding very thin-walled tubing down to.0015 in.

wall and diameters to.010 in.

These products are fabricated of materials such as stainless steel, platinum, iridium and titanium.

Examples of end uses for these components include stents, medical device delivery systems, surgical tools and other medical products.

LSA Laser Services and Automation, also closely held, is an FDA compliant laser component manufacturer specializing in micro welding and machining.

It utilizes 4 axis computer numerically controlled (CNC) laser welding and cutting systems, and computer aided design (CAD) for component design.

Its components are used in guidewires, pacing leads, surgical instruments, electrical leads and assemblies.

Tom Noll, president of LSA, said, 'We believe the combination of LSA and Oeuvre will provide a broader array of precision welding, drilling and cutting services along with greater capacity to meet the joint needs of our growing customer base.' The combined companies will have annual sales in the $2.5 million range, according to Noll.

Oeuvre will merge its equipment and employees into LSA's Plymouth facilities this spring and the newly combined company will employ 13 technical and office staff in 11,000 square foot facilities.

Mark Dustrude, president of Oeuvre, said, 'We are excited about aligning ourselves with a technically strong company like LSA.

This merger will provide our customers with greater technical capabilities as well as expanded capacity.' Dustrude will continue in the new organization as a consultant.

Sunday, December 10, 2006

Device pre-drills before waterjet cutting

Pneumatic device, mounted next to a waterjet cutting head, drills through awkward materials at a specific offset, then the waterjet cut is started inside the pre-drilled hole.

Waterjet cutting can be a valuable tool to many fabricators, but there are certain materials that have always proven difficult to work with. Some materials such as laminated shim stock, certain laminated composites and phenolics, may de-laminate during the waterjet piercing process. WARDJet's Pneumatic Drill allows a hole to automatically be drilled through the material at a specific offset from the waterjet cutting head.

Once the hole is drilled, the waterjet will then start the cut inside the pre-drilled hole.

The CAD/CAM program, IGEMS, can automate this entire process.

In order to use this tool an air compressor capable of 25ft3/min at 90 lb/in2 must be provided.

This will allow these materials to be cut regardless of any necessary holes.

This unique drill feature also comes in useful when cutting high tolerance holes in various steel and stainless steel materials.

By using the reaming capabilities, a customer can pierce the initial hole with the waterjet and then come back and ream it out to get the higher tolerances that are required.

This can be substantially faster then using a waterjet alone to create these higher accuracy holes.

The pneumatic drill feature is available to be mounted on any WARDJet waterjet cutting system.

This is just one of many unique features that WARDJet offers to allow their waterjet to be used in a variety of applications.

If you have a difficult application give WARDJet a call and see what they can offer as they work with you and your team to find the best solution possible.

Laser system cuts flat sheet and tube

A combined, automated, CNC system for laser cutting of tube and flat steel sheet takes less than three minutes to change automatically from the tube to flat steel sheet machining.

It takes less than three minutes to change automatically from the tube machining configuration to flat steel sheet machining - and vice versa - when operating the new Adige LT Combo now available from BLM Group UK. The savings that result from installing this computer-controlled combination laser cutting system are considerable, making it cost-competitive with the alternative of traditional multi-machine operations. The LT Combo is of modular design, which means the system can be configured to suit individual requirements in terms of floor space, machining capacity and the degree of automation involved.

Automation levels range up to the integration of multi-column pallet warehousing for unmanned machining.

The maximum sheet size that can be machined on the LT Combo is 3000mm by 8000mm, while maximum tube section sizes of 225mm (round), 160mm by 160mm (square) and 200mm by 100mm (rectangular) can be machined along a maximum length of 6500mm.

An integral database with a complete range of cutting parameters guarantees repeatability of cutting quality, with the machine control generating the optimum working parameters (cutting power and speed) at any point in the machining cycle.

Machining of flat sheet is completed to a positioning accuracy of 0.05mm and a positioning repeatability of 0.03mm, while 3D design and programming of tubular components and complex tubular structures (frames) is made simple with Adige CAD/CAM Tubework and Assembler software.

Machining programs can be completed in minutes rather than hours, drastically reducing the time and cost of translating a completed design into a prototype or a full-scale production component.

And the end result in either case is improved product quality, especially when the opportunity is taken to re-engineer existing designs of sheet/tubular structures to gain the maximum benefit from the dimensional and profiling accuracy of the LT Combo laser cutting system.