CNC Machines Software Router Information

Automated cell beats stand-alone turret presses

2007-03-07T02:21:00.003-08:00

Since an automated pressworking cell was installed at a heating and ventilating equipment manufacturer, it says new the facility is 50 per cent faster than stand-alone turret punch presses.

A new Finn-Power automated pressworking cell has been installed at one of the Blackpool factories of heating and ventilating equipment manufacturer, Gilberts. Joint Managing Director, Willie Greenwood, comments that as sheet is always available to feed into the machine, the facility is 50 per cent faster than stand-alone turret punch presses of equivalent specification on site. Installed last summer (2001) by Press and Shear, UK agent for the Finnish press manufacturer, the 'A5 Express' cell incorporates a loading station that holds up to three tonnes of material.

A gantry-mounted gripper head delivers single zintec or stainless steel sheets up to 2,530 mm x 1,270 mm and from 0.7 to 2.0 mm thick to the adjacent press in a matter of seconds.

Says Greenwood : 'We operate two CNC turret presses without auto feed, but wanted to raise productivity without increasing overheads.

In addition, there are issues relating to Health and Safety, such as back pain and cut fingers when manually handling sheet.

Automation was the obvious answer so we researched the market for suitable products.

'We chose Finn-Power because the gantry was integrated with the machine rather than being an add-on, so there were no interfacing problems.

The cell was also good value for money, and in addition, I had worked with Press and Shear in a previous job and always found the after-sales service to be good.

'And so it has proved; the performance of the A5 Express with its fully adjustable, hydraulic stroke has been absolutely fantastic in terms of uptime, rate of production and quality of output, and the minimal back-up we have needed has been prompt and friendly.' Gilbert's air distribution, smoke and fire control products, almost exclusively for commercial buildings, require relatively simple sheet metalwork in their construction but are produced in an astonishingly large number of sizes and permutations.

One standard product line, for instance, is available in 1.9 million variants.

It is therefore essential to have flexibility of production, to which end the company's policy is to machine families of parts from a sheet, as pictured in photograph 2, for which this particular batch run was 60-off.

Production Manager, Ian Blackburn, advises that only about 10 per cent of throughput is accounted for by production of identical parts nested on a sheet, in which case they will be commonly used components and are produced in quantities of up to 3,000 at a time.

Comments Blackburn, 'Three tonnes of material on the input table gives us unattended running for more than six hours, so we try to run sequences of jobs that use the same material as much as we can.

The load station is then replenished by lift truck.

On the off-take side, the punched and nibbled sheets are stacked automatically beneath the exit conveyor, a section of which slides to one side from under the sheet.

They are then handled manually for the components to be de-tagged and removed by hand.' The majority of operations are punching and nibbling at speeds up to 600 hits per minute, while traversing at 100m/min contributes further to short machining times.

Some in-cycle forming is also carried out for producing such features as louvres and countersunk holes, plus some embossing for location purposes.

The turret on the Finn-Power is larger than on Gilberts' other presses and more extensive use of multi-tools increases the number of stations available to the point where the need for tool change is rare.

According to Blackburn, the company's products are being systematically redesigned to take advantage of the resulting production flexibility, reducing the need for second operations such as notching and guillotining.

'It allows us to make our products faster, better and more economically,' he said, 'and to set new standards for best practice in our industry.' Greenwood has been encouraged by his first move into automated pressworking and intends to phase in further cells when his other punch presses become due for replacement.

As there are a lot of long, straight machined sections on his products, he says he may well consider the Finn-Power 'Shear Genius' next time to take advantage of its fast right angle shear, which like the gantry is an integrated feature, not an add-on.

He was also impressed at the last metalworking 2002 exhibition in Birmingham with the Finnish company's linear motor laser-profiling machine, which attains cutting speeds of up to 20m/min.

'I always thought that laser machines were for intricate profiling, but very high speeds combined with the absence of tooling costs and lower capital outlay makes them much more attractive for our work,' he says.

'Punch press and laser technologies are converging and it makes sense to exploit the best features of both; we would also consider punch / laser combination machines the next time around.

Multi-tool holders are attractively priced

2007-03-07T02:21:00.001-08:00

Competitively priced, multi-tool holders suitable for CNC punch presses and a new 2.4.1 die system with increased grind life are now available.

A new range of competitively priced, multi-tool holders suitable for CNC punch presses and a new 2.4.1 die system with increased grind life are now available from Wilson Tool International of Swindon. The Multi-tool holders will allow the number of tools carried on a punch press to be significantly increased and the tool change and setting time reduced, which results in improved process flexibility and productivity. Central to the Wilson Tool programme is the launch of its competitively priced five and 10 station multi-tool holders, punches and dies providing a high level of versatility for Trumpf TC 2000R, TC 2020R, TC 5000R and TC 6000L punch presses.

As part of the expansion of the top-selling 2.4.1 (trademark) punch press tooling system which provides an unmatched, double the regrind life of traditional tooling, the availability of the 2.4.1 die incorporates the die holder, die blade and high precision spacers.

These will provide an increase in the regrind life to an unprecedented 2mm.

Users of the Wilson Multi-tools, which are available ex-stock, are totally interchangeable and have the advantage of a highly versatile tooling system which extends the tool capacity of the machine.

Punches and dies are cheaper than standard solid punches, setting time is reduced and the user gains from improved flexibility of the punching cycle.

Standard tool shapes including squares and rectangles are available with Wilson's patented Optima coating which extends tool life between regrinds by up to 500 per cent.

Round tools are Optima coated as standard.

With the Wilson guaranteed delivery, any stock tool ordered before 11.00 am is despatched, from what is believed to be the world's largest tool stock, the same day.

Special tool shapes are shipped within one to two days of drawing approval.

New concept in punch press tooling

2007-03-07T02:20:00.001-08:00

2*4*1 is very simple to set on the machine, guarantees punch alignment, eliminates the need to pre-set tools, and reduces tool change time, from three minutes to just 30 secs.

A totally new concept in punch press tooling has been developed by Wilson Tool International of Swindon for users of Trumpf, Pullmax, Boschert, Euromac and Omes turret punch presses. The new tooling designated 2*4*1(tm) is very simple to set on the machine, guarantees punch alignment, eliminates the need to pre-set tools, reduces tool change time, from, at best three minutes, to just 30 secs, and is able to provide an unmatched double the regrind life of the traditional 'Old Style' tools. The Wilson 2.4.1 tool range covers round, square, rectangular and standard shapes in both flat and 'whisper' designs.

It can also be specified with Wilson's patented Optima high performance coating which can extend tool life between regrinds by up to a further 500 per cent.

Now solely manufactured at the European headquarters in Swindon for export around the world, 2.4.1 has a regrind allowance of 6 mm providing further advantages of reduced tool inventory and replacement purchases with correspondingly increased productivity levels from the machine.

The 2.4.1 design allows direct insertion into the machine and utilises a built-in collar to eliminate any need for pre-set fixturing of the tool away from the machine.

The system also eliminates setting error which can occur with the 'Old Style' tooling because the Wilson development incorporates fixed angle positioning of the punch.

Also, during long production runs and heavy load conditions, the 2.4.1 design overcomes problems when the punch can move in the collar.

The new tooling is available on the standard 'next day' Wilson Tool International delivery service, while any specials are guaranteed within seven to 10 days of design approval.

Flexible sheet metalworking for generator maker

2007-03-07T02:19:00.000-08:00

Two advanced sheet metalworking facilities are nearing completion at the Springvale and Monkstown factories of FG Wilson, featuring six Finn-Power Shear Genius turret punch press cells.

Two advanced sheet metalworking facilities are nearing completion at the Springvale and Monkstown factories of FG Wilson, both sites being located within a few miles of Belfast city centre and a short drive from the company's diesel generator assembly plant in Larne, the largest in Europe. Among the latest equipment to be installed are six Finn-Power Shear Genius turret punch press cells. Valued at a total of £3.5 million, the Finnish hydraulic presses were supplied by sole UK agent Press and Shear Machinery, Tamworth.

In trials, they proved to be 20 per cent more productive for FG Wilson's type of work than the next best turret punch press or system, according to Martin Ross, CNC Production Manager at Monkstown.

Nearly all this advantage is directly attributable to the Finn-Power's built-in shear, which executes straight cuts in a fraction of the time it takes to nibble the edges conventionally with a tool in one of the turret stations.

One Shear Genius is installed in Monkstown whilst the other five are at the new Springvale plant.

The former is operated as a stand-alone cell whose materials handling requirements are met by lift trucks.

The latter machines, however, are linked to a Remmert automated material storage system, delivering blanks to the presses and punched sheets to press brakes and folding machines.

Driven by a kanban production system in Larne, a host computer generates work lists which the press operators pull down to their controls.

Such a high level of investment in a flexible sheet metalworking system was essential to keep pace with worldwide demand for emergency power.

The rebuilding of Kosovo and power rationing in Chile have led to additional orders.

Demand is also growing as the Caribbean prepares for this year's hurricane season and due to widespread fear of power loss at the turn of the Millennium.

Each Finn-Power SG6 cell is virtually identical, comprising an automated sheet loading station fed from the computer-controlled material store and a gantry-type feed mechanism which sequentially transfers sheets measuring up to 1,500 mm x 3,000 mm into the punching, forming and shearing machine.

On the opposite side is a sorting conveyor which automatically allows small punched components to drop selectively into various bins underneath.

Larger items are allowed to continue into a stacking system where similar parts are arranged together onto pallets ready for removal by lift truck.

Meanwhile, the shear cuts up the skeleton for removal by another conveyor to a scrap bin at the side of the machine, eliminating time-consuming handling and cutting of the scrap by the operator.

Smaller pieces of waste material punched from the sheet are routed to a separate bin.

The difference between the Shear Genius and other machines is explained by Martin Ross.

'Sheet metal components for many of our generators are typically the size of a table yet often have corner notches and just a few punched holes in addition to four long straight edges.

One part, for example, requires 50 hits to produce the features and conventionally needed 100 nibbling strokes to cut out the remainder of the periphery, which invariably had scallops and pinch marks.

Overall, I should say around 60 per cent of punch press time in our factories used to be taken up profiling straight lines.

'Using the 800 mm x 1,500 mm shearing blades mounted at 90 degrees to each other in a separate station on the SG6, this latter operation is carried out in just a few strokes and there is no material wastage.

Automatic blade gap adjustment ensures efficient shearing irrespective of the thickness of material being cut.

Another advantage is that all nested components have the punched features completed before the shear separates them, so they leave the working area together and continue their journey automatically by conveyor.

With other punch presses each part has to be removed by hand, extending the overall cycle time.

After that the skeleton needs to be cut up and discarded, adding further to the labour content of the operation.' Three years ago Mr Ross used the 'Sheet Metal Industries' annual punch press review to research more than 30 suppliers on the market, shortlisting three for production trials on a selection of more difficult generator components.

At that time, only one machine other than the Finn-Power had an integral right angle shear but the 2 mm capacity in steel was not high enough.

However the 4 mm capacity of the Shear Genius was ideal as up to 3 mm galvanised and uncoated mild steels account for 95 per cent of FG Wilson's punching work and there is spare power to ensure that the machines do not have to work to their full rated capacity.

Larger generator fuel tanks and bases, canopies and other components are machined from heavier gauge steel on existing punch presses, laser cutters and plasma machines at the Monkstown plant, which is also serviced by an automated storage and retrieval system.

Apart from the speed of cutting straight lines, another major issue at the time of machine evaluation was to ensure that the presses could deploy sufficient tools to produce all FG Wilson's parts without repeatedly having to exchange tools in the turret.

This has been achieved by maximising the use of multi-tools carrying either six medium size tools or 10 smaller tools and buying a sufficient number of machines so that each may be dedicated to one gauge of sheet.

This policy will be fully implemented when the other Finn-Power cells are installed, which incidentally will have the new, larger Finn-Power turret.

At the same time, a certain amount of presently subcontracted sheet metalwork for canopies will be brought in-house, helping to amortise the investment quickly.

Meanwhile, one of the Springvale presses is changed over periodically, a process which takes about half a day, to meet demand for generator bases and heavier gauge canopies made from 2.5 mm and 3.0 mm galvanised steel.

The other two machines are already dedicated to 1.2 mm, 1.6 mm, and 2.0 mm gauge material, producing guards, control boxes, cover plates and, on one machine, canopies as well.

An interesting comment made by Martin Ross was that, as FG Wilson is an OEM, its production department is able to, and does, influence generator designs to rationalise the number of punch press tools needed.

In contrast, subcontractors do not have that luxury as they are normally required to produce exactly what their customers ask for.

Joe Hanna, Production Manager at Springvale, commented: 'All our presses work hard, 24 hours a day, five days a week and at the weekends as well.

During one week at the end of June we punched 25,500 parts.

The higher level of business means that batch sizes are increasing; it is not unusual for us to produce 180 canopies in a week and even more of other parts.

It can sometimes take a whole shift to complete two jobs.' Cycle times vary from two to 15 minutes, according to component complexity, but in some cases cluster tooling is required to achieve these times.

Five of the eight auto indexing stations in each machine are equipped with multi-tools whilst the other three have tools for producing corner notches and radiused features.

Wilson turret tooling accounts for 90 per cent in use in Monkstown and Springvale.

Special tools are used to upform louvres and countersinks in many of the components, helped by the ability on all Finn-Power machines to program infinitely variable stroke lengths and speeds for each tool.

Product development is carried out in Larne and designs are networked from the Autocad system directly to the sheet metal factories where they are translated into DXF format.

This is recognised by Finn-Power's JETCAM SG system running on a PC which assists in program preparation including punching and forming operations, automatic nesting of parts to maximise sheet utilisation and operation of the right angle shear.

Up to 432 components (locking tabs) are punched from a single sheet although at the other end of the scale just one part, a canopy roof, may be produced.

Programs, of which there is currently a library of 2,500 at Springvale (increasing all the time as work is transferred from Monkstown) are downloaded to the machines by DNC link.

Power Link MMC is a further Finn-Power option which FG Wilson has adopted.

It is a high-speed data connection to the CNC system designed to simplify monitoring and identification of a machine fault.

If an error occurs, a unique code appears automatically on the screen of the CNC with full textual explanation of what the problem is and how it should be solved.

In addition, a schematic image is displayed of the relevant area of the machine.

Additionally, a full user manual for the punch press is included, so not only is the service manual on-line but also the operating instructions for machine, control and accessories.

A third function is NC file management.

As a result of these Shear Genius installations and a number of other Finn-Power machines operating across the Province, Press and Shear has now employed a resident engineer for Northern Ireland who lives 15 miles from Belfast.

FG Wilson was established in 1966 in an old textile mill in Belfast, Northern Ireland.

In the early 70s the company started to focus on the design and manufacture of diesel-powered generating sets, since which time the company has experienced spectacular growth.

A small, family run, general engineering firm has grown into a large, internationally renowned exporter with subsidiaries and dealers on every continent.

In June 1999, Caterpillar acquired 100 per cent equity in FG Wilson.

Caterpillar reports annual sales of over US$ 20 billion, with engines and generating sets accounting for over 20 per cent of turnover.

Today, FG Wilson is the largest diesel generating set manufacturer in Europe and third largest in the world, with annual sales of more than œ250 million.

It is one of the largest employers and exporters in Northern Ireland with 90 per cent of generating sets exported to over 170 countries.

The company lies comfortably within the UK's top 100 exporters and has won the prestigious Queen's Award for Export Achievement three times in the last decade.

FG Wilson manufacturing plants boast state of the art facilities and are among the most advanced in the world.

Since 1993, the group headquarters has been located in Larne, shipping in excess of 30,000 generating sets per year.

The high export volume is supported by two other plants in Northern Ireland, at Springvale and Monkstown, with extensive facilities for metal fabrication and the manufacture of control systems.

CNC punch presses have large turret capacity

2007-03-07T02:18:00.000-08:00

Robust, thick turret tooling style CNC punch presses, 200 and 300kN, offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.

Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.

A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.

Bridge frame construction provides accuracy and durability.

LVD's latest punch presses handle workpieces up to 1524 x 2500mm depending on model.

Larger workpieces are handled with clamp repositioning.

Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.

* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona's high-speed operation while reducing noise and shock.

Fully programmable stroke profiles and patented Smart Stroke feature maximize punching performance and provide flexibility for punching and forming applications.

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.

Up to 48-station turret capacity - Verona's large and versatile double-track turret provides flexibility and easy set- up.

Every station accepts shaped punches and dies, reducing set-up time.

A unique mix of turret stations provides exceptional capacity.

Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.

The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.

The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.

Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.

* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.

This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.

The punch press accommodates the latest in tooling technology for high-performance fabricating.

These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.

Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.

Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.

* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.

Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.

* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.

LVD's automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.

Verona may be integrated with a robotic Pick-Sort material handling system.

The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.

The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.

* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.

Cosmetic finish tooling for CNC punch presses

2007-02-27T22:00:00.001-08:00

In response to a request to apply a cosmetic finish to components from a turret punch press, Wilson Tool International of Swindon has developed a special tool to produce a hexagonal surface pattern.

In response to a customer request to apply a cosmetic finish to certain components produced on a turret punch press and avoid the cost to purchase specially finished material and suffer any extended lead time for supply, Wilson Tool International of Swindon has developed a special tool to produce a hexagonal surface pattern.

The tool was originally developed for use on a Trumpf punch press.

However, tools can be produced by Wilson to create a wide range and combination of cosmetic shapes and finishes as part of the automatic CNC cycle for all types of punch presses in material up to 1.2 mm thickness.

Comprehensive FMS makes sheet metal parts

2007-02-27T21:59:00.002-08:00

A flexible manufacturing system for sheet metal components is able to offer integrated component production involving a turret punch press, laser profiling and right angle shearing.

The LVD Omega flexible manufacturing system (FMS) for sheet metal components is able to provide fully integrated component production involving a turret punch press, laser profiling and right angle shearing, combined with fully automatic loading and unloading, component sorting and stacking and sheet storage and retrieval. And, such is its modular development criteria that individual elements can be added, removed and updated as needs change. Central to the flexibility of the system is the large table configuration which provides the capability to handle sheet sizes up to 1575mm by 4025mm through the punch, laser or shear, without the material having to be repositioned, regauged or reclamped.

The first fully integrated system has been installed in Europe at electrical equipment maker Grenier Group in Kerzenhein, Germany to provide some 2,500 different blanks ready for forming.

Because the system incorporates warehousing, an intermediate buffer zone and the ability to remove scrap material, without interrupting the operational cycles, fully automated multiple shifts are now run at the plant.

The company is now capable of almost triple production by processing some 3,500 tonnes of material in a year with higher added value.

Previously, it was limited to 1,200 tonnes.

It now operates with shorter cycle times and the high number of individual components are more easily handled.

The Omega based FMS can be provided with a wide range of material handling options from simple auto-load to full warehousing.

A storage tower system can also be configured to suit customer requirements.

Central to the system is the high productivity Omega 1500 turret punch press with up to 10 Auto-Index stations of 88.9mm diameter and an indexable multi-tool with three or eight stations and 0.01 deg incremental orientation positions.

The Omega is a 300kN hydraulic powered machine able to process material up to 8mm thick at 325 hits/min, nibble at 750 hits/min and has a maximum rate of 1,000 hits/min.

The specification of the integrated laser adds options of 1,500, 2,000 or 3,000W fast flow, CO2 laser power with quick change lens and NC focus.

The right angle shear gives the option to shear nested blanks rather than punch or laser cut.

The large 1500mm by 1000mm blade has a progressive shear action which allows shearing across the entire length of the sheet.

Capacity can be specified at 4mm or 6mm with programmable clearance and scrap separation.

The single GE Fanuc 32-bit control is able to operate the entire FMS system including punch, laser, shear, storage and automation which simplifies the operators task, monitoring and programming.

Full digital technology, with a user terminal linked to the CNC via optical interface, incorporates a Windows environment.

Laser punch proves twice as quick as nibbling

2007-02-27T21:59:00.001-08:00

A Finn-Power LP-6 combination laser cutting and punching machine from Press and Shear has brought major benefits for Cambridgeshire-based St Neots Sheet Metal.

A Finn-Power LP-6 combination laser cutting and punching machine from Press and Shear has brought major benefits for Cambridgeshire-based St Neots Sheet Metal. By purchasing the machine complete with automated loading and parts sorting systems, the company has been able to achieve very high levels of machine usage, much of it unmanned. Moreover, materials utilisation is higher - a benefit of more flexible nesting - while the clean edge available with laser cutting eliminates labour intensive de-burring prior to assembly.

Comments Wayne Matthews, a director of St Neots Sheet Metal, 'Before we installed the LP-6 we were putting a significant amount of complex profiling work out to third parties for laser cutting.

However, when we decided to buy our own machine we were very keen to install a system that provided both laser and punching facilities.

The benefit of the combination machine comes not so much from its ability to punch holes and other shapes very quickly as from its forming capability.

By having access to a single-pick-up profiling and punching / forming resource we have been able to produce highly accurate work, but the lead time on complicated flat patterns is very short.' St Neots Sheet Metal is a well established supplier of high quality sheet metal components and sub-assemblies to a variety of industry sectors.

These include electronics companies, air conditioning system suppliers and point-of-sale display manufacturers.

The family-owned company offers a full range of production, assembly and finishing services from prototype development through to series production.

Manufacture is in batch quantities from one-off to 10,000-off although 100 to 200 is more usual.

Around 85 per cent of material processed is between 1 mm and 2 mm thickness; most of this is mild steel though the company also produces components in aluminium, stainless steel and Zintec.

'We tend to concentrate on precision fabrication work,' said Mr Matthews.

'We regularly maintain feature position tolerances of ñ 0.1 mm, whilst our more general tolerance is ñ 0.4 mm.

Ours is an all-CNC fabrication shop using Finn-Power punching machines as the principal source of flat patterns.

We have operated a TP 2020 from the same Finnish manufacturer for nearly six years and this is partnered by a TP 2525 which is just under five years old.' When it elected to purchase a laser-punch, the company examined all of the options available to it.

There were a number of points in favour of the Finn-Power LP-6 which commended it over the alternatives, as Mr Matthews explains.

'We have had good service from Press and Shear with the other two machines so any alternative vendor would have needed to demonstrate a convincing technical advantage.

As it is, the Finn-Power machines are very advanced in their facilities and also offer the benefit of modular construction.' He continues, 'If at some time in the future we wanted a larger turret or needed to add a tapping attachment, we could have them retrofitted.

We bought the machine with automated loading and the Sub-8 parts sorter which is fed by the work chute, but we may well add an off-load system for skeleton and large parts removal.

An additional advantage for us has been the ability to use our existing tooling on the new machine.' St Neots' LP-6 cell combines 30 kN of punching power via a 20-station turret with a 2.5 kW Triagon laser capable of cutting up to 9 mm thick mild steel.

Maximum punching diameter is 89 mm.

The machine is fitted with Finn-Power's patented upforming station which recesses form tools when not in use and thereby prevents scratching of the material underside.

A brush-type table also preserves surface finish and minimises noise during punching.

Maximum sheet size is 3,000 mm by 1,500 mm and it is loaded automatically by a transfer device which incorporates sheet detection and measurement.

This ensures that each new sheet has separated successfully from the stack.

In addition, the cell incorporates a scheduling system which, given availability of the required tooling and material, allows multiple jobs to be set up for sequential production.

'Automated loading is a big advantage for the operators as it would otherwise be difficult to man-handle large sheets or thick material,' Mr Matthews adds.

'The system has worked very well.

Part of this is down to our having done our homework before we bought the machine to ascertain how it would impact on production.

For instance, we calculated that about 75 per cent of the components we make would fit down the 550 mm square work chute opening to be collected by the Sub-8, so we knew that the machine could operate minimally manned.

We had also identified the existing components that would be best suited to production on the laser-punch.' Production on the Finn-Power LP-6 relies largely on a standard kit of turret tooling with odd shapes or non-standard hole sizes produced by the laser.

Because most of the material is between 1 mm and 2 mm thick, it is possible to use a compromise die clearance to cover the majority of jobs without tool changing being necessary, other than for job-specific forms.

All long edges are laser cut, with the marginal time penalty compared with using slitting tools more than compensated for by the elimination of manual de-burring.

Laser cutting is speeded by the use of pre-punched start holes.

This reduces the energy needed for piercing and eliminates spatter onto the cutting head optics.

It is also invaluable when processing plastic coated materials.

'Nesting and material utilisation have both improved with the LP-6 because we can use common line cutting or position parts more closely together,' Mr Matthews concludes.

'On complicated profiling work the laser is at least twice as quick as nibbling on a turret punch but its greatest value is in the process flexibility and value that it provides.

Components coming off the machine are usually ready for bending with no intermediate work required and this has had a positive impact on our direct costs and competitiveness.'

Turret punch press suits OEMs and subbies

2007-02-27T21:58:00.000-08:00

Following extensive world-wide market research involving the future demands of both OEMs and sheet metal subcontractors, LVD/Strippit has developed the Global 20 CNC turret punch press.

Following extensive world-wide market research involving the future demands of both OEMs and sheet metal subcontractors, the new LVD/Strippit Global 20 turret punch press provides a combination of high productivity, large sheet capacity and an increased turret size with additional auto-index stations. The Global 20 design brief also incorporates a new or retrofit interface for modular automation packages such as automatic sheet loading and unloading, part sorting and picking. Based on a bridge frame construction to maintain high orders of stiffness, the Global 20 delivers axis positioning speeds of 110 m/min.

Included is the flexibility of a 30-station turret with less than one second station to station index time.

There is a choice of three or four auto-index positions.

The machine uses GE Fanuc 180i PC-based control and drives package.

The Global 20 is the first completely new machine from the joint LVD and Strippit design and development team combining leading punch press expertise from Europe and America.

The machine will be built in both the LVD Belgium factory and the Strippit plant in Akron, New York State for marketing around the world.

The Global 20's modern design creates an ideal punching machine platform to process work pieces up to 2500 mm by 1250 mm and 6 mm thickness without repositioning to an accuracy of +/- 0.10 mm and repeatability of +/- 0.05 mm.

A servo-driven hydraulic ram is fully programmable, has a 200kN punching force, is capable of producing 800 strokes/min and provides high flexibility for punching and forming applications.

The incorporation of Strippit's patented Smart Stroke, maximises productivity without operator or programmer intervention.

With Smart Stroke, the punching cycle is optimised through automatic determination of the hover height of the ram based on material thickness and distance between holes.

Turret configurations for thin or thick style are available, each with replaceable hardened steel bush guides to reduce wear.

Three 88.9 mm Auto-Index stations are included as standard with the option of a fourth for higher tool capacity.

Tooling flexibility can be further enhanced with inclusion of three, eight or 30 station Multi-Tools.

In addition, indexable Multi-Tools can be used to expand the number of auto-indexable tools.

Choice of brush, ball transfer or 50:50 ball/brush tables are available giving improved sheet support and quiet operation.

The three programmable work clamps, included as standard, can be individually programmed to a position on the X-carriage and relocated to a new position within the part program.

This feature virtually eliminates 'no punch' zones.

A programmable work chute of 450 mm by 500 mm is included.

The PC-based GE-Fanuc 180i control considerably reduces set up times and being Windows-based provides powerful features such as diagnostics, increased program storage and networking.

CNC turret press gets automatic work handling

2007-02-27T21:55:00.000-08:00

A new, fully automatic load / unload and component sorting system is available for FINN-POWER's all-electric 'Work Centre E' turret punching and forming press.

A new, fully automatic load / unload and component sorting system is available for FINN-POWER's all-electric 'Work Centre E' turret punching and forming press, which incidentally now has the additional options of laser profiling equipment and a 6-station tapping unit. Designated LUR, the gantry-style load and unload robot is positioned to one side of the punch press in a relatively compact arrangement to enable minimally manned or lights-out production of components from 180 mm by 150 mm upward. Work Centre E already has a measure of automation through incorporation of a parts conveyor to off-load components up to 500 mm square.

Addition of the LUR greatly extends this range, offering the opportunity to automatically load sheet from a stack, off-load finished components onto designated stacking positions, and manage removal of the sheet skeleton.

Manufacturers are therefore able to take full advantage of automated production as there is no need to de-tag and sort components following a period of unattended working.

LUR comprises four main elements, being the gantry robot with vacuum-type gripper, the loading wagon for blank sheet, an unload gripper and wagon for sheet skeletons, and a stacking wagon for profiled components.

The sorting capability of the robot is virtually unlimited, allowing set-down of up to 3,500 kg of finished components anywhere in the stacking area.

Design of the off-load gripper has been tuned to allow handling of formed as well as flat components.

In addition, the electronic interfacing with the machine control allows the unload gripper to move in and hold the component during the final nibbling strokes, ready for immediate off-load with minimal interruption to profiling activity.

Turret press tool clamp has replaceable cylinder

2007-02-23T03:32:00.003-08:00

Wilson Tool International has developed a range of clamp assemblies for Amada turret punch presses that incorporate a replaceable air/hydraulic cylinder.

Wilson Tool International has developed a range of clamp assemblies for Amada turret punch presses that incorporate a replaceable air/hydraulic cylinder. The new clamp eliminates the cost incurred to replace the complete clamp assembly due to wear or breakdown because the cylinder is fully integrated into the main framework of the original clamp. As well as standard clamps, Wilson Tool International has stocks at Swindon suitable for all types of material including heavy duty applications.

Here, Wilson recommends its carbide upper clamp with a knurled lower plate.

When marking the material is an issue, urethane boots can be supplied for the upper clamp units in conjunction with smooth lower clamps.

As part of the Wilson retrofit design, parts of the clamp are fully compatible with the original machine design and individual elements can be supplied via the Wilson next day delivery service.

Alignment fixture sets older Trumpf tooling

2007-02-23T03:32:00.001-08:00

A new alignment fixture for setting old-style Trumpf punch press tooling is now available from Wilson Tool International of Swindon.

A new alignment fixture for setting old-style Trumpf punch press tooling is now available from Wilson Tool International of Swindon. Due to its simplistic design, Tru-Set can be purchased for a quarter of the price of existing tool alignment fixtures. The Wilson Tru-Set bench-mounted fixture which can be used on all types of Trumpf-style collar tooling including size 1 and 11, the Minimatic style, heavy duty, manual and even forming tools which do not have integral collars.

Flat punches and punches with shear can also be set and the unit is supplied with a range of accessories and a regrind length chart.

In use, Tru-Set can accommodate 0, 45deg and 90deg angle settings and comprises two sliding setting bars in order to datum both small and large tools.

Each bar runs in precision ground guideways, with the small tool setting bar designed to contact a flat ground on the shank of the tool.

Tools are set relative to the locating key and then pinch-bolt tightened ready for use with the tool secured in the fixture.

The feature can be used in conjunction with a wide range of punch presses from Trumpf, Pullmax, Omes, Euromac, Kunz and Boschert.

Positioning speeds raised on CNC punch press

2007-02-23T03:31:00.001-08:00

The TC5000R introduces a new weight optimised co-ordinate guide system, lighter machine tables and rapid tool change cartridges to give 20m/sec2 acceleration and positioning speeds of 116m/min.

The TC5000R introduces a new weight optimised co-ordinate guide system, lighter machine tables and the use of rapid tool change cartridges made from carbon fibre. The result is acceleration values of 20m/sec2 and positioning speeds of 116m/min. This Trumatic is the latest addition to the Trumpf Trumatic range of punch presses - a machine whose emphasis is firmly on productivity.

Several design features contribute to its outstanding performance including a new guide system, proven punching head, increased c-axis speed, faster tool change and highly efficient materials handling.

The hydraulic punching head operates at 1200 hits per minute during punching and 2800 for marking.

The machine can process material up to 8mm thick and 230kg in weight.

Trumpf's advanced stripper control allows downward pressure of the stripper to be varied between 4.5 and 20kN from stroke to stroke through the programme control.

On the TC5000R, the c-axis rotation has also been increased to 330 rpm.

This allows much faster contouring and tapping.

The same applies to forming.

Thanks to the closed hydraulic control loop and measuring system, variable forming height ensures minimal stroke travel.

A new bending tool allows right angle forms up to a maximum of 25mm.

Beading forms can also be processed at high speed with the maximum of 2800 hits per minute.

Height adjustable clamps for holding the material are now offered, making it possible to form next to the clamps.

Weight reduction means tool change time is quicker on the TC5000R.

Tool set up is also simplified and downtime reduced thanks to a central clamp locking system for all tools in the linear magazine.

In common with other machines in the Trumatic range the TC5000R guarantees easy operation through open control technology and WindowsT interface.

On line help and integrated diagnostic functions help shopfloor personnel to understand and eliminate any problems.

Trumpf's Teleservice supports this should expert intervention be required.

In keeping with the TC5000R profile, the modular automation options available are also built for speed.

The new SheetMasterT system is almost 50% faster than its predecessor, which in turn boosts the productivity of the TC5000R even more.

Punch press faults interrogated remotely

2007-02-23T03:30:00.002-08:00

Following the introduction of new WindowsT-based software, users of the Trumpf TC 500R can now benefit from Trumpf Telepresence - a remote fault interrogation service.

Following the introduction of new WindowsT-based software, users of the Trumpf TC 500R can now benefit from Trumpf Telepresence. Through the built-in modem, Trumpf specialists can remotely interrogate any faults. With a worldwide installed base of more the 2000, Trumpf's TC 500R punching machine continues to be the flagship of the range.

Its appeal can largely be attributed to its ability to maintain or improve productivity levels as batch sizes fall - a significant problem faced by many punch press users.

Users of turret machines in particular, who account for the lion's share of TC 500R UK sales so far, report significant improvements in cost efficiency.

The main benefit is substantial reduced set-up times.

This is due to the combination of head rotation - which reduces the number of tools required - and rapid tool exchange, derived from an ability to pre-set fully all tools away from the machine.

Rapid changeover however, is only one of many TC 500R benefits.

Speed of operation, fast hit rates and positioning speed, a large working area and exceptional material utilisation through retractable clamping, all have the their part to play.

So too does head rotation that allows all tools to be rotated.

Now with the introduction of new WindowsT-based software, this already reliable machine can take advantage of Trumpf Telepresence.

Via the built-in modem, Trumpf specialists can remotely interrogate faults on the machine.

In addition to cosmetic changes to the machine such as a new hood for the hydraulic head, the latest model of this workhorse is now available with brush tables for total scratch-free operation with pop-up rollers to aid initial sheet loading.

Punch tool maker issues sheet metal booklet

2007-02-23T03:30:00.001-08:00

A 12 page booklet depicting a wide-range of accessories for the sheet metal industry has been published by Wilson Tool International of Swindon.

A 12 page booklet depicting a wide-range of accessories for the sheet metal industry has been published by Wilson Tool International of Swindon, the world's largest independent manufacturer of punch press tooling. The booklet covers products from slug ejectors to tool cabinets and trolleys and includes items such as diamond files, punch lubricants and sprayers, bushings, tool presetters, brush dies, clamps and a demagnetiser.

Sheet metal punching FMS has two cells

2007-02-15T01:17:00.001-08:00

Britain's leading ride-on garden machinery manufacturer, Countax, has installed a GBP1 million sheet metalworking cell in a purpose-built extension to its Oxfordshire factory.

Britain's leading ride-on garden machinery manufacturer, Countax, has installed a GBP1 million sheet metalworking cell in a purpose-built extension to its Great Haseley, Oxfordshire factory. The flexible manufacturing system (FMS) comprises two FINN-POWER Shear Genius punching, nibbling and shearing cells with component sorting and stacking facilities, fed from a 12-bay tower capable of storing 33 tonnes of sheet metal. Supplied last year by Press and Shear Machinery, the Finnish-built FMS works round the clock supplementing four older FINN-POWER TP2525 turret punch presses on site.

The new system was needed to meet increased production of components for 15 models of Countax tractor and rider mower plus 13 variants of cutter deck and various attachments.

Around 2,000 part programs are stored and more are being created all the time owing to the regular introduction of design modifications and new models.

Managing the project is Nick Whitman who comments, 'Two aspects of the FMS are worthy of special mention.

First, the proven shearing facility integrated into the two punch presses drastically reduces the time needed to cut straight lines.

For example, one side of a chassis member can be sheared in a couple of seconds with two strokes of the one-metre blade, whereas nibbling the same length used to take nearly two minutes and the edge finish was not so good.

'Secondly and unusually, FINN-POWER was willing and able to modify one of the Shear Genius machines so that it could be accessed from the opposite side.

This allows us to supply sheet metal from a single tower store to both machines by placing them back to back and at the same time to remove all sorted components and skeletons from one side of the FMS.

Reprogramming of the two conveyors feeding the sheet in either direction was necessary to ensure uninterrupted production on both machines.

The execution of all this has been flawless.' Countax started making garden tractors only 10 years ago and its growth has been meteoric.

The company is now the number one British manufacturer exporting up to 40 per cent of output; and its GBP23 million turnover last year will grow significantly in the current financial year owing to the recent acquisition of competitor, Westwood Engineering, Plymouth.

For most of the 1990s, the use of FINN-POWER equipment has been central to the successful implementation of sheet metal manufacturing on site and will continue to be for the foreseeable future.

Said Nick, 'It was by no means a foregone conclusion that we would continue with Press and Shear and FINN-POWER just because we had been using the TP2525s, even though they have been very good and are still operating reliably today.

They were one of the first hydraulic punch presses on the market and were quieter and had a higher punching capacity than the mechanical presses we considered at the time.

'We were, and still are, satisfied that FINN-POWER is among the leaders in the field technologically - if not the leader - but we still looked at all the major suppliers when we decided to invest again, this time in a lights-out, automated sheet metalworking system.

What swung us in favour of the incumbent punch press supplier was the good service we have received in the past.

We have never had to wait more than a day for a service engineer to arrive, and normally only a few hours.' Within three months of installation the FMS was working 24 hours a day.

An interesting feature is the remote monitoring and optimisation of Countax programs from Finland.

Nick says that it was eerie the first time he saw the machining parameters being changed on screen without the apparent intervention of anyone.

FINN-POWER engineers periodically log on remotely to evaluate speeds, feeds and other machine settings to see if they can be improved and to make the appropriate adjustments, not only to the machines but also to the material storage and handling elements of the system.

Fault diagnosis and advice is also easily provided from Finland over the same direct link.

Nick points out that modern punch presses are considerably more efficient than their predecessors.

The Shear Genius achieves 400 hits/min at 25mm hole centres, which is 50 per cent quicker than the TP2525.

The ballscrews have also been uprated to enable faster traversing speeds up to 100m/min.

He is also impressed with the effectiveness of the programmable clamp repositioning which allows about seven per cent more sheet area to be utilised by moving the clamps automatically during the cycle to present otherwise dead areas of the sheet to the turret tools.

The FMS at the Great Haseley factory is devoted to processing 2.5m by 1.25m sheets of mild steel of gauges between 1mm and 3mm, with some galvanised steel in the thinner range.

If a repeat program is not to be used, a newly designed component is downloaded from the company's 3D modelling CAD system to a Radan computer-aided manufacturing station which unfolds the part if necessary, writes the program for the Shear Genius and produces a tooling list.

This information is then downloaded directly to the appropriate punch press control.

Contributing to high production output is good planning of the tooling in the turrets of both Shear Genius machines.

Countax has worked closely with Wilson Tool which has provided tool/die sets with clearances able to span a range of material gauges.

For example, sheet in the range 1mm to 1.6mm thick may be punched with the same tooling, and so on.

Furthermore, careful attention has been paid to how the nine auto indexing stations are utilised in each of the 20-station turrets.

Seven of the nine stations carry indexing tools to produce slots at a variety of angles, avoiding tying up the non-rotating stations with tools set at fixed angles and the frequent tool changes that this would have necessitated.

The other two auto indexing stations in each turret are equipped with multi-tools, one containing eight tools and the other 10.

Punches in the diameter range 3mm to 20mm (the maximum is 24mm) are housed in these stations as well as a couple of square and rectangular tools.

In all, 72 tools are deployed across the two turrets and sheet is fed to the machine which is equipped with the appropriate tools to complete any particular set of nested parts.

In practice tool changes are rare - maybe one per Shear Genius per week compared with two or three a day on the TP2525s due to the smaller number of auto indexing tools.

In common with all modern FINN-POWER machines, the Shear Genius has the ability to up-form features to a maximum height of 16mm using a station in the lower portion of the machine frame to lift the die up towards the tool.

It is also possible to tap the walls of circular up-forms.

Nick is currently evaluating this technology as it would prove useful for producing formed features in bag lids and deck stiffeners which currently go onto a press for a second operation.

Coated tooling available for Wiedemann presses

2007-02-15T01:16:00.001-08:00

Wilson Tool International has launched a new range of turret punch press tooling specifically to suit Murata Wiedemann machines.

Wilson Tool International the world's largest independent manufacturer of punch press tooling has launched a new range of turret punch press tooling specifically to suit Murata Wiedemann machines. The new Wilson Tool range includes 10 standard shapes for 112 and 114 style tools as well as special forms, standard and non-standard keying locations and will allow the award-winning Wilson Wheel Tool to be applied for cost-effective forming and slitting. A major productivity advantage to Wiedemann users will be the availability of Wilson's patented Optima high performance coating which can extend tool life between regrinds by up to 500 per cent.

With the tool coating, galling is reduced on the tips of the punch and corner breakdown is far less of a problem.

Wiedemann's punches can be supplied flat or with roof top shear while special shear styles can be produced to order.

Stripper options are available as customised moulded strippers as well as standard 70dA, which is a very light duty stripper, through to 95dA for heavy duty applications.

Available within the Wiedemann 114 style punch and die adapter set is the award-winning Wilson Wheel range of tooling.

Wheel Tools are available for rolling shear, rolling pincher, rolling offset and rolling rib applications.

In addition, a series of special shaped punches can be specified as well as tooling options involving special tolerances, widths, clearances, die reliefs, lands or ejector holes.

Laser development relationship announced

2007-02-15T01:15:00.002-08:00

Jenoptik AG and the Trumpf Group have entered into a cooperative relationship in the high-performance diode laser sector, aimed at development of high-performance diode laser technology

The technology group Jenoptik AG and the Trumpf Group have entered into a cooperative relationship in the high-performance diode laser sector, aimed at joint further development of high-performance diode laser technology for industrial applications. Retroactively as of January 1, 2001, Trumpf is acquiring a 25.1 percent share of Jenoptik Laserdiode GmbH, a company in the Jenoptik Photonics division. Until now, Jenoptik Laserdiode GmbH was 100-percent owned by Jenoptik, Laser, Optik, Systeme GmbH in Jena.

The remaining 74.9 percent remains with the laser and optic specialist from Jena, Germany.

Jenoptik Laserdiode GmbH (JOLD) develops, produces and distributes high-performance diode lasers.

These high-performance diode lasers are being utilized by Trumpf as pump sources in the solid-state lasers manufactured by its subsidiary Haas-Laser.

'Two companies, each market leaders in their respective fields, have joined forces here.

The interplay between diode manufacture and industrial application will quickly lead to innovative approaches and new spheres of application,' said Professor Dr.H.C.

Lothar Sp„th, chairman of the board, Jenoptik AG, at the joint press conference in Munich on Tuesday.

Sp„th added that for Jenoptik, this partnership was a logical extension of its strategy to work closely together with the technological and market leaders of different business sectors.

'After ASML in the high-performance optics sector and Heidelberger Druckmaschinen AG in the digital camera sector, we have now gained a third powerful partner in Trumpf,' Sp„th said.

Powerful Growth in High-Performance Diode Lasers Lasers in industrial production are a key technology, the economic importance of which greatly exceeds its direct sales figures.

This growth sector is characterized by innovation and dynamics: 'This acquisition will enable Trumpf to cooperate in a technology that is important for Trumpf lasers.

Because of their compactness and high degree of efficiency, high-performance diode lasers have highly promising future prospects.

Diode laser technology has enormous growth potential - and as such is important for the continued development of Trumpf as world market leader for industrial lasers,' said Professor Berthold Leibinger, managing partner of the Trumpf Group.

Because of the strong market growth in the high-performance diode laser sector, Jenoptik is investing around 11 million euros in a new clean-room building at its Jena site, including production machinery for the mass production of high-performance diode lasers.

Production is due to begin as early as this year.

For fiscal year 2001 Jenoptik Laserdiode GmbH is planning to increase its sales by more than 50 percent on the previous year.

Reduce tool change time from 3 mins to 30 seconds!

2007-02-15T01:15:00.001-08:00

A 'totally new concept' in punch press tooling has been developed by Wilson Tool International of Swindon for users of Trumpf, Pullmax, Boschert, Euromac and Omes turret punch presses.

A totally new concept in punch press tooling has been developed by Wilson Tool International of Swindon for users of Trumpf, Pullmax, Boschert, Euromac and Omes turret punch presses. The new tooling designated 2*4*1 is very simple to set on the machine, guarantees punch alignment, eliminates the need to pre-set tools, reduces tool change time, from, at best three minutes, to just 30 secs, and is able to provide an unmatched double the regrind life of the traditional 'Old Style' tools. The Wilson 2.4.1 tool range covers round, square, rectangular and standard shapes in both flat and 'whisper' designs.

It can also be specified with Wilson's patented Optima high performance coating which can extend tool life between regrinds by up to a further 500 per cent.

Now solely manufactured at the European headquarters in Swindon for export around the world, 2.4.1 has a regrind allowance of 6 mm providing further advantages of reduced tool inventory and replacement purchases with correspondingly increased productivity levels from the machine.

The 2.4.1 design allows direct insertion into the machine and utilises a built-in collar to eliminate any need for pre-set fixturing of the tool away from the machine.

The system also eliminates setting error which can occur with the 'Old Style' tooling because the Wilson development incorporates fixed angle positioning of the punch.

Also, during long production runs and heavy load conditions, the 2.4.1 design overcomes problems when the punch can move in the collar.

The new tooling is available on the standard 'next day' Wilson Tool International delivery service, while any specials are guaranteed within seven to 10 days of design approval.

Turret press processes larger sheets

2007-02-15T01:14:00.000-08:00

The LVD/Strippit Global 20 turret punch press shown for the first time at a European exhibition provides a combination of high productivity, large sheet capacity and an increased turret size with additional auto-index stations. The Global 20 will be demonstrated with full automatic sheet loading and unloading, part sorting and picking. Based on a bridge frame construction to maintain high orders of stiffness, the Global 20, now available from LVD (UK) of Marlow, delivers axis positioning speeds of 110 m/min.

It includes the flexibility of a 30-station turret with less than one second station to station index time and a choice of three or four auto-index positions.

The machine uses GE Fanuc 180i PC-based control and drives package.

The Global 20's modern design creates an ideal punching machine platform to process work pieces up to 2500 mm by 1250 mm and 6mm thickness without repositioning to an accuracy of +0.10mm and repeatability of +0.05mm.

A servo-driven hydraulic ram is fully programmable, has a 200kN punching force, is capable of producing 800 strokes/min and provides high flexibility for punching and forming applications.

The incorporation of Strippit's patented Smart Stroke, maximises productivity without operator or programmer intervention.

With Smart Stroke, the punching cycle is optimised through automatic determination of the hover height of the ram based on material thickness and distance between holes.

Turret configurations for thin or thick style are available, each with replaceable hardened steel bush guides to reduce wear.

Three 88.9mm Auto-Index stations are included as standard with the option of a fourth for higher tool capacity.

Tooling flexibility can be further enhanced with inclusion of three, eight or 30 station Multi-Tools.

In addition, indexable Multi-Tools can be used to expand the number of auto-indexable tools.

Choice of brush, ball transfer or 50:50 ball/brush tables are available giving improved sheet support and quiet operation.

The three programmable work clamps, included as standard, can be individually programmed to a position on the X-carriage and relocated to a new position within the part program.

This feature virtually eliminates 'no punch' zones.

A programmable work chute of 450mm by 500mm is included.
The PC-based GE-Fanuc 180i control considerably reduces set up times and being Windows based provides powerful features such as diagnostics, increased program storage and networking.

Punch press adds flexibility to furniture-making

2007-02-08T23:03:00.001-08:00

To turn material into value added product and with maximum flexibility, Bisley Office Furniture has invested in Pivatic coil processing equipment and a Finn-Power Pivatic P40 turret punch press.

With annual turnover of GBP72 million, Bisley Office Furniture is Europe's largest producer and supplier of steel office equipment. Its factories at Woking, Surrey and Newport, Gwent are the UK's largest users of sheet steel outside the car industry with combined monthly consumption of 3,500 tons - all mild steel in thicknesses from 0.7mm to 1.2mm. To assist in turning the material into value added product efficiently and with maximum flexibility, the company has invested recently in Pivatic coil processing equipment and a modern Finn-Power turret punch press, all built in Finland and supplied through sole UK agent, Press and Shear Machinery, Tamworth.

Bisley has recorded 20 per cent year on year growth for some time and is now the market leader in the UK, which absorbs 70 per cent of production.

This position has been achieved through a combination of effective marketing and cost-effective production.

While the basic cuboid shape of filing cabinets, cupboards and filing units is well established, the way in which the components are produced and the manner of their assembly is subject to continuous review and improvement.

This is supported by ongoing investment in modern sheet metal processing equipment.

The Newport factory in particular is a Mecca for sheet metal processing practice with capability to service batch processing requirements from one- to 20,000-off.

Newport engineering manager Paul Ostrolenk explains, 'We complete over 10,000 finished cabinets per week and process all of the sheet metal in-house.

Everything we manufacture is made to order - we supply both own-branded and customer-branded products.

Although they are nominally standard and break down into eight main product lines, there is huge potential for variation in height and width as a result of which we have 5,000 live components.

Hence we need considerable flexibility in our manufacturing resources to achieve rapid order turnround.' To that end the factory boasts a wide variety of manufacturing equipment.

It ranges from stand-alone machines to automated lines capable of taking in sheet material at one end and ejecting assembled cabinet outer casings in a range of sizes and varieties.

Likewise a recently installed, computer controlled, powder paint line can switch between different colours in seven minutes.

This need for flexibility led directly to installation of the first Pivatic coil processing line, a Pivatic P40.

Different ranges of Bisley cabinets use the same internal shelf positioning system based on four pressed formed panels with a series of horizontal slots to provide alternative shelf locations.

Owing to cabinet height variation these are needed in different lengths - which more or less rules out the use of hard tooling.

However the components are not well suited to production on a conventional punch press either.

Production engineer Tony Cottrell commented, 'We used to make them on our turret punch presses but the nature of the components meant that we were losing a lot of material as scrap.

There was also a great deal of manual handling involved which is not ideal on long, narrow parts produced from fairly thin gauge material.

The Pivatic machine allows us to produce the flat blank from coiled material bought in to the exact width of the finished component.' The Pivatic P40 uses a cassette-type tool system which provides four A-stations, three B-stations, three C-stations and two D-stations.

These accept thick turret tooling which is Bisley's standard punch tool system.

Positioning is achieved through a combination of coil feed and lateral movement of the cassette, while length is determined using a dedicated shear.

'It has proved to be a very cost effective means of producing these components,' said Mr Cottrell.

Apart from the slugs there is no waste material and coil is cheaper than sheet in any case.

One small regret is that we did not order the P40 line with a stacker, as we initially intended to go straight from punching to pressing.

This proved impracticable as we may produce up to thirty different product lengths from each coil; altering length on the punching line is literally a push button exercise whereas it would take much longer to change a press line over.

Later on when we bought the P80 we installed it with an off-load stacker table.

However this line is used for a wider variety of components as well as backing up the P40 on shelf location production.' Both Pivatic lines combine reliability with ease of use, operating round the clock for five days a week plus overtime.

Programming is straightforward and has encouraged use of the 800mm capacity P80 for a wide range of components.

Ease of programming and good levels of service back-up experienced with the Pivatic lines were factors in the installation of Bisley's first Finn-Power turret punch press, an F5-25.

Paul Ostrolenk said, 'Our policy on new machine purchases is to buy in the most appropriate system at any given time.

In the case of punch presses, a number of factors including speed, accuracy, build quality and service are at the top of the list; price is a secondary consideration.

There were a number of features on the Finn-Power that recommended it.

One was certainly the single track turret as all tools have equal access to all parts of the sheet - which triple track designs do not - and we also liked the machine control's capability to accept programs straight off our network.

Punching speed and ease of set-up were also factors.' Punch press profiled components at Bisley are manufactured from both standard sheet and cut blanks according to requirements.

General positional tolerance on punched features is 0.1mm, opening to 0.25mm on forms, mainly countersinks.

With 8-station and 24-station multi-tools on the F5-25, Bisley has 50 tools available in the 20-station turret including three indexing stations.

The machine is used for diverse production requirements as the company's punch pressing capacity is used both for lower volume production work and as a facility to supplement production on hard tooled resources.

As a result, relatively few turret punch jobs are scheduled for more than five hours of production per week.

This explains why the otherwise highly automated factory employs no punch press automation.

Mr Cottrell concluded, 'The Finn-Power has proved to be a very good machine.

The single track turret gives us complete flexibility on tooling placement, which is a big advantage in terms of setting up and leads to fewer compromises in programming.

Likewise the ability to program clamp positions gives us more freedom as to where we put features and speeds up re-setting.

From an operator's point of view the brush table makes it relatively quiet in operation and the conveyorised scrap removal system is a good feature.

Sheetmetal CNC punching cells multiply

2007-02-08T23:02:00.002-08:00

FiFab celebrated its 25th anniversary by buying a new punching facility from Trumpf. The investment was not just one machine, but a flexible cell, based on a Trumatic 500 and automatic handling.

The Kingdom of Fife is no longer restricted to a well-defined area in eastern Scotland; it now stretches as far west as California and as far east as Japan. Glenrothes-based Fife Fabrications - more succinctly known as FiFab - produce sheet-metal components and electronic assemblies. The last seven years has seen a four-fold increase in their turnover to more than GBP10 million, with a commensurate increase in the size and spread of their domain.

Prominent in their customer base is a series of blue-chip, multi-national companies.

It includes household names in computers, telecoms, avionics, and general electronics.

Fife products are therefore found in all parts of the industrialised world.

Founded in 1972 FiFab, like many sheet-metal sub-contractors at that time, built its early manufacturing facility around turret-punches - several of which served the company well for its first quarter century.

However, conscious of it's need to improve both productivity and flexibility to meet ever increasing customer expectations, FiFab celebrated its 25th anniversary by buying a new punching facility from Trumpf.

The investment was not just a punching machine, but a flexible manufacturing cell, based on a Trumatic 500 and incorporating SheetMaster automated material load and unload.

Not only did this facility enable long periods of unmanned operation, but - perhaps more importantly - it enabled FiFab to help its clients reduce their 'time-to-market'.

This was so successful that it was joined by a second identical cell a year later.

FiFab's spectacular growth has been due in no small measure to the vision and drive of MD Archie Smith, who has always striven to produce his clients 'leading-edge' products on appropriately 'state-of-the-art' equipment.

However, modestly but rightly he will claim that the successful implementation of new manufacturing philosophies has been a team effort.

The success of the Trumpf installation is down to the enthusiasm with which his team has embraced and exploited newer ideas and processes.

Success breeds success, but improvements breed yet higher expectations- particularly from customers who demand ever-greater flexibility and ever-more rapid responses.

So yet more investment was needed.

In Archie Smith's words 'We had already taken one successful step up the technology ladder, and now another one was necessary.' But this was not a small step for man - more a giant leap for manufacturing - it involved not just buying another machine, not even buying another flexible cell, but buying a GBP1.5 million FMS incorporating four machines with full material storage and handling.

At the heart of the new system are two of Trumpf's new TC5000 punch-presses.

In evolutionary terms these machines - with their faster head rotation, higher hit rates, and above all high accelerations - mark as big a step forward as the 'old' TC500 did over its predecessors when launched some 10 years ago.

Each of the new machines will be fed with material by a new SheetMaster load and unload device, which is also noticeably faster than its predecessor.

The improved speeds of processing and handling are such that on typical electronics and telecoms components, time-savings of between 25 and 35% will be experienced.

Like the TC500s, the new TC5000s each have an 18 station linear tool magazine mounted on the X-axis guide rail.

However, one of the new machines is equipped with a Trumatool automated tool-store.

This option enables an additional 40 tool-sets to be stored 'live'.

As with the standard linear magazine, all stations can hold all tools including Multitools.

As all tools are rotatable, the tool capacity of this particular machine is theoretically of the order of several hundred.

This enables a number of different jobs to be produced without manual intervention.

But a bigger benefit to companies such as FiFab - who produce for low batch, 'tool-intensive' industries such as electronics - is the ability with Trumatool to exchange tools for resetting or refurbishing without interruption to the machine-cycle.

A further benefit to FiFab will be the ability to inject an urgently required 'one-off' into the middle of a larger running batch, and to do it as Archie Smith's adds - 'At the flick of a switch.' The two TC5000 cells with their SheetMasters are in turn linked to a twin-tower material store of 31 locations, that provides an automated supply of raw-material to the cells at any hour of the day, night, or week-end.

When a new programme is activated from the job queue in the machine control, it will - after checking the availability of both tools and material - send for a pallet of appropriate raw material from the store.

This is delivered to a location under the SheetMaster from which individual sheets are loaded to the machine.

In processing, medium and large components are removed to pallets and stacked in known locations, and can be subsequently fork-trucked to follow-on operations.

Smaller components, scrap-pieces, and punch-slugs are dropped into bins and similarly trucked away, as are residual material skeletons once they have been removed from the machine-table by a Trumagrip device.

The original material pallet, along with any unused material is returned to the store, put back in and the stock is appropriately adjusted, and ultimately re-ordered.

In addition to the above-mentioned FMS- comprising twin TC5000 cells and store - the existing two TC500 cells, will be re-located and linked to a duplicate 31 station automated store to create a double FMS facility.

This will be the largest in the UK, and one of the largest in the world.

In preparation for this installation FiFab has completely re-planned its shop-layout.

Thanks to the use of the two automated stores, this has enabled the company to release some 300m2 of floorspace from material storage to more value-adding activities.

In association with Trumpf, Fife Fabrications, is in the process of creating a truly world-class manufacturing facility to match its reputation as a supplier of world-class products to an international client-base.

Punch press tool maker has set up in Germany

2007-02-08T23:02:00.001-08:00

Extending its customer support programme for punch press and press brake tooling, Wilson Tool International Europe has built a customer support and technical centre near Hannover, Germany.

Extending its customer support programme for punch press and press brake tooling, Wilson Tool International Europe has built a 960m2 customer support and technical centre at Rodenberg, just 25 Km west of Hannover in Germany. The inaugural 'first dig' was performed by Mr Ernst August Meir, Mayor of the town on 22 May with Colin Blackwell managing director European Operations and Klaus Ludwig Neumann European Sales Manager. Set on a 5,000m2 site purchased by Wilson Tool, the new 960m2 facility will include a 320m2 technical centre and is due to be opened in December to service Germany, Holland, Belgium, Switzerland, Austria, the East of Europe and former Russian areas.

Wilson Tool set up its current customer operations in Germany in 1987 under Klaus Ludwig Neumann, European Sales Manager.

Since then, the market has grown at a rate of 15 per cent each year.

There are no current plans to manufacture tooling at the facility, instead customers will benefit from the fast and well-proven next day service from the UK for standard tools and the fastest currently available for specials.

Says Colin Blackwell Managing Director of Wilson Tool International Europe: 'The objective of the Rodenberg facility is to build closer relationships with customers, perform seminars on tooling, tool management and tool service and provide front line problem solving.

A further benefit of the technical centre which will feature installations of punch presses and press brakes from leading manufacturers will be to and stage a permanent tooling exhibition.

The site is within a 25 minute drive of Hannover airport and close to the important trunk road network providing quick access to service the whole European mainland.

Also, with major exhibitions being staged at Hannover Messe, this will provide a vital communication link for Wilson Tool.

Maintains Klaus Neumann: 'Our customers demand production flexibility and ever higher levels of service to support the growing installations of punch presses.

Growing use of automation and new machine designs, the need to run around the clock and problems in obtaining and retaining labour capable of running ever smaller batch sizes, means we have to be slick, professional, proactive and competitive to meet customer needs.' The move to the new premises will take place between Christmas and New Year which will mean no loss of customer service.

Latest CNC punching cell ups floorspace usage

2007-02-08T23:01:00.003-08:00

Among reasons cited for an order for a TC5000 cell were productivity improvements of 30-40% over an earlier TC500 and 3-4 times as much work out of the floorspace vacated by an exisiting TC240.

Among reasons cited for an order for a TC5000 cell were productivity improvements of 30-40% over an earlier TC500 and therefore an ability to get 3-4 times as much work out of the floorspace vacated by an exisiting TC240. For some years now the name Broxton has been synonymous with quality sheet metal sub-contract. However, this alone is no longer fully descriptive of Broxton's comprehensive design and manufacturing service.

From being a typically reactive sheetmetal sub-contractor, they have, progressively, over the last three years and under the guidance of MD Marcus Ellams, become a highly pro-active and innovative provider of sheetmetal design and manufacturing solutions to an ever-widening range of clients.

A visit to their Cirencester facility shows how they have done this and achieved a 50% growth in the last 12 months alone - quality and professionalism exude from everything that they do.

The arrival of Marcus Ellams at the company led to the introduction of new customer services, new management ideas, and investment in new technology.

They have become a market leader in the design and manufacture of electronic enclosures - creating a 'one-stop shop' by adding finishing and assembly operations to their 'best in class' sheetmetal facility.

They have evolved an innovative employee empowerment structure, that has led to production personnel taking full responsibility for direct customer contact in the making and maintaining of order promises.

Nearly 21/2 years ago they invested in a flexible sheetmetal cell - comprising a Trumatic 500 with SheetMaster.

Their investment in the TC500 cell was, in its way, as significant a step forward as their very first venture into CNC had been with a TC240 in the mid 1980's.

It was the first time that an English sub-contractor had made such an investment, and in Marcus Ellams' own words - it enabled them to enter the 'Premier League'.

From the very first day after commissioning, the facility has run 'lights-out' at night and in every week since installation they have averaged more than 100 hours of production.

On weekdays the facility is minimally manned, an operator being present to prepare and pre-set jobs to provide material and remove batches of finished parts.

On weekday nights the cell runs unmanned until its load is complete, which is usually between 4 and 12 hours.

At weekends a duty operator makes periodic visits to site to remove and replenish material, but on a Monday morning the machines run-time clock invariably shows that they have achieved at least 45 hours of production since Friday afternoon.

The output of this cell has been the major factor in enabling Broxton to meet a significant increase in demand for services.

When a company achieves the growth rates that Broxton are experiencing, a policy of continuous investment becomes a necessity.

They had, by now, experienced the real productivity benefits of working larger standard sheets on full head-rotation machines.

Replacing an older TC240 machine with a TC500 would have significantly increased punching capacity - without an increase in the floor space required.

However, their need for a new machine coincided with the launch of Trumpf's new TC5000 - which offered even greater benefits.

Therefore, for the third time in 15 years, Broxton have shown their conviction in new technology and Trumpf's ability to provide it, by ordering one of the first TC5000's in the UK.

Among reasons cited for this order were productivity improvements of 30-40% over the TC500 and therefore an ability to get 3-4 times as much work out of the floorspace vacated by the current TC240.

It would also provide the means to maintain keen unit prices in an increasingly competitive market.

A further attraction was the Trumpf Multishear tool used to achieve highest edge quality at fastest profiling rates; this is very important in the quality conscious market in which they operate.

And last but by no means least was the ability to retro-fit a SheetMaster onto the TC5000, which will unlock the potential of unmanned night and weekend working in the near future.

Broxton know that a major factor in their success is their ability to offer a quality service to their customers and acknowledge that a major constituent of this is their world class machinery, such as their new TC5000 from Trumpf.

Microtagging produces a lean fabrication activity

2007-02-08T23:01:00.001-08:00

B/E Aerospace's fabrications department has met the lean challenge by introducing Wilson Tool International's microtagging system, which has improved workflow and reduced second operations.

If you have ever flown in a Boeing airliner, the chances are that your journey will have been spent sitting in a seat produced by B/E Aerospace. The company has a strong presence in the UK, with factories in England, Wales and Northern Ireland and recently, the English site, at Leighton Buzzard, has responded to the challenge of market demands by instigating a lean manufacturing programme. As part of that exercise, the sheet metal fabrications department has been very closely involved with Wilson Tool International of Swindon to provide valuable technical input on tooling technology.

As a result, the adoption of microtagging, on-machine part marking using Wilson's dot marking system and in-process forming of countersinks are just three initial changes to create important results.

Enhancements to B/E Aerospace working practices have led to significant improvements in work flow, reduced second operation processes and savings of 30 hours of production time a week.

Mark Sutton, cell supervisor for the punching department, commented: 'Six months ago we would punch out a batch of components, wait for them to be deburred and then second operation any countersinks or part marking.

This created a bottleneck; even though we had four people working on deburring they just couldn't keep up.

Now with micro-tagging, we only need two people deburring.

We also have a good work flow which applies to part marking and countersinking.

From a quality angle, we've benefited from using Wilson's Slug-hugger dies as they eliminate any under surface scratching.

Our turn-around on urgent jobs has also improved considerably.' B/E Aerospace is also progressively adopting Wilson's 2.4.1TM tooling system, which enables the effective operational life of its punch press tooling to be doubled.

Wilson's 2.4.1 was originally developed for fixed head tooling applications such as those found on Trumpf, Pullmax and Euromac punch presses.

It has the key advantage of increasing the regrind life of an otherwise standard tool through the use of a precision ground spacer.

The tool system also incorporates direct keying which allows quick and simple loading of punches into the machine without any need for pre-setting.

Mark Sutton explains: 'Wilson's 2.4.1 is one of those simple ideas that makes you wonder why no-one did it years ago.

As we constantly use a lot of slotting tools, this means we are expecting to see a significant reduction in tool costs.' Ed Close, the B/E Aerospace technical engineer involved with the lean manufacturing project comments: 'Although we have purchased tooling from Wilson Tool International for some time, we had never taken advantage of their technical training services.

However, the lean manufacturing project provided an incentive as we were targeting cost reductions through improved methods.' He continued: 'From our involvement with Wilson we learned a lot and have been able to put some of the ideas into practice straight away.

Both microtagging and part marking came directly from their seminars.

But what is important is our longer term thinking because we now appreciate 'cause and effect' in respect of tool performance and how correctly applied tool maintenance benefits tool performance and hence part quality.' He follows on to outline as they now know where to look, they will probably find tooling will last far longer.

'The seminars certainly opened our eyes to what is possible however, we still have to balance these improvements against our re-programming workload.

But most important, we know there is still a large potential for additional savings.' The fabrication shop at Leighton Buzzard is equipped with a wide variety of quality equipment.

The main sheet metal profiling resources are a pair of Trumpf Trumatic 240R punch presses bought in the early 1990s.

Fabrication requirements range from small brackets to large boxes, in batches between 10 and 10,000 and most are dynamically nested on 2 metre by 1 metre standard sheet.

Around 75 per cent of material processed is aluminium, however, some steel and stainless steels have to be machined.

Material thickness ranges from 0.5mm up to 5.0mm, though the average tends to be around 0.9mm and part complexity can require up to 16 bends.

In addition to flat patterns, a number of blanked components are also produced.

While B/E Aerospace has been able to achieve significant improvements through a relatively modest investment in tooling for the 110,000 part numbers that it currently produces, around 44,000 are sheet metal components.

Ed Close acknowledges there is considerable potential for improvement in production methods but is equally sure that a slightly cautious approach is called for.

'Before we go too far, too fast,' he says, 'we need to analyse where we can get the most benefit.

If we substantially alter the way that a component is produced, it can then mean altering or re-writing the part program.

That's obviously going to be more cost-effective if the part is in regular manufacture and produced in large batches.

In addition, because we're making parts for aerospace application, we need CAA approval for any changes in the manufacturing process.

'With that said, we've already seen significant benefits from lean manufacturing initiatives and Wilson's input has definitely assisted us along that path.

There are areas where we could do more on the punch presses.

One is the use of form tools for cold form threading to replace the use of threaded inserts,' says Ed Close.

The company is also considering how certain other components might be more accurately and economically produced by using Wilson developed progressive tooling for use on the punch presses.

For instance, the shop recently completed a batch of 10,000 match-box sized brackets.

These were shaped like a squared-off table tennis bat and the first part of the punching operation entailed using a radius tool to produce six curved external corners.

A similar tool was used to produce two internal corner radii.

'A progressive type blanking tool will cut the time on that part dramatically and we are currently discussing the possible adoption of this technique,' says Ed Close.

The combination of lean manufacturing practices with technical advice from Wilson Tool has worked well for B/E Aerospace.

So far, the productivity benefits have been quantifiable and are on-going.

But, equally important is the effect on morale.

As Mark Sutton concluded: 'We've learned a lot, been able to put significant improvements into practice and have seen the benefits come through quite quickly.

That's encouraged us as a team to try other ideas, which means the lean manufacturing process is beginning to gain its own momentum.'

Slitting die tooling offers longer regrind life

2007-02-08T23:00:00.001-08:00

Slitting die tooling system for CNC punch presses uses a tough and wear-resistant premium tool steel for the slitting die blade to offer twice the regrind life of standard tooling.

The Wilson 2-4-1 Slitting Die system is the latest innovation developed by Wilson Tool. The 2-4-1 Slitting Die system offers twice the regrind life over a standard solid die. The Slitting Die blade is manufactured from Ultima, a premium tool steel which is tough and resistant, excelling in applications which demand long-term wear resistance and toughness.

Ultima can further extend the tool life by up to 400% compared with a standard die, representing considerable cost-savings on replacement tooling.

The special die insert, exclusive to Wilson Tool, is fully supported by the die base which is made of a special shock-absorbent steel designed to resist the repeated impact that can sometimes cause conventional dies to crack.

As the die insert is reground, the shims supplied with the assembly can be used to return the die assembly to the correct height.

When the die insert wears out, a new 2-4-1 insert can be purchased for less than the price of a standard replacement die.

Trumpf CNC punch/laser presses get faster

2007-01-30T23:36:00.002-08:00

Fast at punching, unbeatable at forming and highly flexible thanks to state-of-the-art laser technology - that's the new combination machine Trumatic 6000 L.

Fast at punching, unbeatable at forming and highly flexible thanks to state-of-the-art laser technology - that's the new combination machine Trumatic 6000 L. It gives you start-to-finish processing with batch times so far unattainable by any other machine - whether it's laser processing, punching, forming or marking. And it's cost-effective even for short runs.

The hydraulic punching head works at 900 strokes per minute during punching, and 2800 strokes a minute during marking.

It has a programmable presser foot (stripper) that can also be used actively if required.

Here it makes contact with the sheet a fraction of a second before the punch.

The press-down force can also be varied from stroke to stroke via program control with the new Advanced Stripper Control (ASC) function.

The stripper thus adapts to the respective machining situation.

During forming, a variable forming position ensures minimal stroke travel.

Beading can be done almost at punching speed, thanks to the hydraulic closed loop.

The new Laserpress has at its disposal the further developed Trumpf TLF laser series with higher outputs - 2000, 2700 and 3200W.

They enable higher cutting speeds.

The laser is integrated into the machine in a space-saving manner, and protected by air cushions from vibrations during punching operations.

During laser cutting, the non-contact automatic height regulation system maintains a constant standoff between the cutting nozzle and the workpiece.

This enables the laser to cut components that have already been formed.

A quick-change system enables the cutting head to be exchanged in one easy step.

The machine can also be equipped with the programmable focus adjustment feature AutoLas, which, until now, was available only on flatbed laser machines.

The open control guarantees easy operation.

A user interface developed by Trumpf is very similar to the Windows one.

During error diagnosis, the function sequences are shown in pictorial form, and correction measures are displayed in plain text.

The machine is equipped for teleservice, with detailed diagnoses of the hydraulic system and all other functions.

For the expansion of the Trumatic 6000 Laserpress into a flexible machining center, all the systems offered by Trumpf have available as options: an automated sheet metal and finished part store, systems for automatic loading and unloading, a newly developed system for virtually scratch-free ejection of small parts, plus the automatic tool storage and change system Trumatool.

The Trumatic 6000 Laserpress attains its full functionality with ToPs 300.

The programming system is ideally tailored to the machine, and guarantees a fully functioning processing chain.

Punch press tooling capability put on a plate

2007-01-30T23:36:00.001-08:00

Plate provides design engineers with a quick reference guide to the type of features and operations that can be performed on a computer controlled punch press.

Developed to provide design engineers with a quick reference guide to the type of features and operations that can be performed on a computer controlled punch press, Wilson Tool International, the largest independent manufacturer of punch press tooling in the world, has produced a sample plate showing typical features and applications that can be performed. Available free of charge from Wilson Tool's Swindon Technology Centre, the sample plate includes three hinged panels with the all the parts and features produced on a punch press. There are standard and special 2-D shapes, special forms, countersinks, stiffening ribs, offsets and louvres produced in the sample.

In addition examples of different engraving and marking, logos, extrusions, bridge lance and forms, thread forms and EKOs.

Disc lasers cut glass with zero kerf width

2007-01-25T05:20:00.000-08:00

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.

Many years of experience and competence as well as a high performance service network worldwide guarantee reliable and stable operation at the customer's site.

Slab laser has 5kW for high cutting speeds

2007-01-21T23:18:00.000-08:00

To offer increased cutting performance, a 5kW diffusion cooled CO2 slab laser with a high energy density to provide improved process stability and high quality at high cutting speeds.

In response to customer's needs for increased cutting performances, Rofin introduces the DC 050. With an average output power of 5,000 Watts this diffusion cooled CO2 Slab laser provides an ideal laser source for industrial plate and sheet cutting applications. 'We are glad to enlarge our CO2 product range with this new model,' said Thorsten Frauenpreiss, managing director of Rofin-Sinar Laser.

'The newest model of the mature DC series provides new possibilities for all cutting applications - especially for thick plate applications where the high-performance laser proves its quality.' Due to the excellent beam quality of the laser and its increased output power, high-pressure cutting with long focal lengths is now available in the 5kW power range, too.

Additionally, the high energy density provides improved process stability at high cutting speeds, a precondition for reliable cutting data and quality.

Thanks to the patented design, the low-maintenance Rofin CO2 slab lasers are easy to service.

Having no gas circulation, the laser does not need any turbines.

The gas bottle that is required for the gas exchange every 72h, is positioned conveniently within the laser head, so that an external gas supply is not necessary.

The laser beam that is produced in the resonator is uncoupled by a diamond window without any losses of power or beam quality.

The internal water-cooled mirrors, are robust and non-wearing reflective optics.

With its excellent beam quality of K0.9 this laser is at all power levels a perfect tool for manifold cutting and welding tasks.

* Live-Demonstration of Ultra Large Scale Remote Welding - the DC 050 showed its outstanding qualities as a welding laser together with the remote welding system (RWS).

In a live welding demonstration of vehicle rear seats, 49 welded joints are created within 12s.

The RWS is a high speed welding system, which is able to make multiple spot welds in an arbitrary pattern over a very large working area in a short time.

The variety of possible welds is nearly limitless, spots, circles, lines, waves or any other form.

Thanks to easy programming and beam forming through the mirror and scanner all applications can be set up quickly.

With a RWS a very wide working area is possible, because the laser beam is expanded by a telescope and focussed by an optic on the work piece.

Using a focal length of up to 2.0m gives a working area of 2900 x 1800 x 1000mm.

With a positioning speed of 400m/min between the welding points, known as 'rapid move', the non- productive time is reduced to a minimum.

This provides the shortest possible cycle times.

With about 20 million welding cycles for more than 300km of weld length, without the exchange of typical wear parts, the system also sets a benchmark for availability and process optimization.

The laser is positioned above the working area so that, compared to a conventional manufacturing method like, e g, resistance spot welding, a compact system with the smallest possible footprint results.

* Patented CO2 laser technique for remote welding - the Remote Welding System was shown at the euroblech fair in combination with a diffusion- cooled Rofin DC 050 with a average output power of 5kW.

This CO2 laser belongs to the patented Rofin DC series.

The excellent beam quality of K0.9 makes the use of remote welding cost-effective.

As all DC lasers have a perfect basic specification for high speed welding with large focal lengths, they are the ideal tool for this application.

When quick welding for complex formed work pieces is required, the Scanner Welding System (SWS) with a robot is the perfect solution.

At the EuroBLECH, Rofin will present this mirror deflection system in combination with a 6-axis articulated robot.

The mirrors offer extremely quick positioning (<50ms) of the laser beam within the considerably extended working area of about 200 x 240 x 80mm.

In comparison with the already industrially used RWS with its CO2 laser, in the SWS all three scanner axes are coupled with those of the robot so that the combined system has nine accessible axes.

Like in the Remote Welding System, weld geometry can be programmed freely, which means it can be adjusted specifically to the requirements of the component.

Furthermore, the sophisticated software has features that calculate the track inaccuracies of the robot so that the weld path is accurate to <0.1mm.

The resulting reduction of non-productive time allows an increase in laser on time from typically 30% to over 80%.

* Perfect features for scanner welding - the Rofin Disc Laser To be able to follow the movements of the robot, a flexible beam guide through fiber optics is needed.

At the EuroBLECH the SWS was presented in combination with a diode- pumped disc laser.

The emitted laser light of this laser can be coupled with virtually no power loss into fibre optics of only 200 micron core diameter.

Compared to rod lasers this new solid state laser generation is distinguished by its nearly doubled efficiency and its improved beam quality of 8mm x mrad.

Because of this beam quality the working distance to the work piece can be increased to up to 400mm with the SWS.

Thanks to this extended distance, the danger of contamination of the optics can be significantly reduced, and the associated greater energy density leads to higher process stability.

At the EuroBLECH Rofin also presented the new DL-R series as cost-effective and compact tools especially for laser hardening and surface treatment.

Based on the mature DL series, these lasers have a wavelength of 940 to 980nm and rectangular beam geometry made for the hardening process.

Thanks to the homogenized beam profile and its resulting uniform energy distribution, large hardening depths are possible without initial melting.

The geometry of the rectangular focus spot is adaptable to match the specific needs of the customer's application.

The DL-R series was designed with Stack Management as a basic feature to ensure laser up-time.

Currently, four laser variations from 900 to 3,600W are available.

An online performance test and the observation of all important parameters provide highest availability - the pointing laser with green wavelength offers a better visibility.

The compact and low maintenance diode lasers have an overall efficiency of 30% and meet typical diode lifetimes far in access of 10,000 hours.

* Laser marking - the ideal tool for small order quantities - the ideal tool for small order quantities, different materials and forms: portable, air-cooled and almost maintenance- free.

The EasyMark can be programmed by effective LaserCAD-Software from any computer and operates from a common mains power supply.

With a wavelength 1064 nm the machine can mark metal and plastics precisely.

Optional program-controlled axes (a linear Z-axis and an axis of rotation with ring admission) can be integrated easily.

After a short period of instruction, the integrated focusing and positioning aids make for easy handling of the machine.

CNC laser profiles faster, has height sensing

2007-01-21T23:15:00.000-08:00

CNC laser profiling system has a laser that is up to 2.4 times faster than a conventional laser profiling machine and flying optic with automatic height sensing - meaning no material marking.

WRES has invested in excess of GBP 400,000 on a Bystronic Byspeed 3015 equipped with 4400W resonator. The machine is one of the fastest laser profiling machines available in today's market, capable of cutting 600 holes/min. Situated on the Nuffield Industrial Estate in Poole, Dorset, UK, WRES was established in 1967 as a welding/repair and reclamation shop.

Today, headed up by managing director Alan Hamer and his son Westley, a team of 25 is dedicated to providing its customers with a first class service from its new purpose built 16,000ft2 factory.

With 40 years experience in the production of precision fabrication, privately owned WRES combines the established traditions of value, service and workmanship with the latest technology.

Using CAD/CAM extensively in the early stages, simple sketches can be converted into a precise working drawing with minimal delay, thus providing cost effectiveness along with totally co-ordinated production.

The company is a major supplier of small components and highly polished stainless steel railings and fittings to Sunseeker International, the world's leading manufacturer of luxury yachts.

WRES also supplies bespoke parts and projects for food processing machinery.

Additionally, the company has quoted and delivered on various projects to detailed specifications and exacting standards for the defence industry; is involved in the architectural sector supplying stairways and balustrades etc for the building market, and has supplied pressure vessels up to 10 tonnes for the petro-chemical industry.

Renowned for its welding and fabrication services, the company specialises in coded MIG, TIG and MMA welding as well as providing a complete range of manufacturing processes which include press braking, guillotining and punching.

Its single source capability extends to in-house milling, drilling, turning and includes chemical and hand polishing.

Through carefully selected specialist sub-contractors the company also provides waterjet cutting.

100% of the laser cutting service, which in the past had been sub-contracted out, has now been brought in-house since the acquisition of the Byspeed.

According to Hamer the addition of the Byspeed fits perfectly into the future vision for the further expansion of the company.

'We recognise that in today's markets price, quality and customer satisfaction are paramount.

The Byspeed is one of the most advanced laser machines on the market today, allowing us to produce basic to complex profiles, delivered to exact specifications.' He said: 'We looked at a number of lasers and visited various users, the majority of whom told us that Bystronic machines were the 'Rolls Royce' of laser cutting.

In addition, the knowledgeable and professional manner with which Bystronic handled the project was impressive.

We were dealing with a company with an ethos very much like our own - customer service and satisfaction being the priority.' Hamer aded: 'The Byspeed uses the latest technology and the Bysoft software with disc file conversion enables us to receive drawings in formats such as dxf, iges, dwg, geo, wmf and postscript thus ultimately saving the customer time and money, resulting in a raised standard of service and improved delivery times.

Quality and service cannot be compromised by high costs.' Laser cutting offers WRES many benefits including zero tooling costs making it an ideal option for prototype work and batch work, guaranteed accuracy to 0.1mm and a burr-free finish meaning reduced production times.

In addition to the general benefits of laser profiling the Bystronic Byspeed boasts a laser that is up to 2.4 times faster than a conventional laser profiling machine, an automatic shuttle table to allow continuous cutting, a flying optic with automatic height sensing meaning no material marking, dissimilar parts nesting to allow profiles of different shapes to be cut from the same material sheet, minimal thermal distortion as well as a maximum sheet capacity of 3 x 1.5m.

The Byspeed is able to cut stainless steel (up to 20mm), mild steel (up to 25mm), aluminium (up to 12mm), copper, titanium, zintec, montel, brass and armour plate meaning WRES can handle a wide variety of customer requirements.

Hamer concluded by saying: 'To our regular and potential new customers WRES offers a free local delivery service, a 'platinum' next day cutting service, no minimum order charge on quantity, no programming costs on client-supplied digital drawings, minimal costs for conversion of non-digital drawings, mill certificates and certificates of conformity and importantly, our guarantee of quality and satisfaction.'

Laser cutting/profiling system varies power

2007-01-13T23:45:00.000-08:00

Laser cutting machine is equipped with a high performance 5.2kW system that is capable of increasing and decreasing its power precisely at the desired point and without delay.

Bystronic UK exhibited at the MACH exhibition for the first time under the Bystronic name since the combining of the Pullmax and Edwards Pearson companies at the beginning of 2006. Visitors to the stand were able to view a wide range of products from across the company's comprehensive portfolio. Laser cutting was represented by the successful Byspeed 3015 equipped with the high performance Bylaser 5200 ARC.

This laser source is capable of increasing and decreasing its power precisely at the desired point and without delay, and with a constant output power of no less than 5.2kW permits the processing of steel sheets up to 25mm in thickness consistently, accurately and quickly.

The Adaptive Radius Control (ARC) technology ensures that the diameter of the laser beam remains constant over the whole cutting area.

The Byjet 3015 waterjet system to be shown will feature two shuttle tables (all Bystronic waterjet systems are equipped with the additional shuttle table as standard) and automatic swivel load/unload.

The twin shuttle tables increase productivity by up to 30% and allow for further automation.

In addition the machine is equipped with two parallel High Precision Tool (HTP) cutting heads which work with even greater precision and faster repositioning times.

The Bypump APC high pressure pump, with active pressure control, incorporates an extensive and automatic diagnostic system that monitors and displays more than 20 signals.

* press brakes - Bystronic offers a wide range of press brakes from the Hammerle 3P range to the Beyeler PR range to the AFM EP series to ensure customers choose the correct machine to meet their bending needs.

Two Beyeler machines were on show at MACH.

The first machine has a bending length of three meters and a pressing power of 100 tonf (100kN).

It also features the award winning Integrated Process Control (IPC).

IPC controls the bending angle without the use of mechanical measuring equipment and without intervention in the control or the need to change parameters.

The second Beyeler PR machine featured an ABB industrial robot to form a highly efficient bending cell.

This cell produces a high quality product that is independent of an operator as well as increased productivity of up to 42% and requires the minimum of space.

The AFM EP series press brake to be shown fulfils the highest demands placed on process reliability by users.

When this is paired with a comparably low purchase price, this machine represents, for individual users, an extremely cost effective, reliable machine with the support and backup of the Bystronic organisation.

The bending and mechanical sector of the Bystronic stand also features a ByShear VR which produces a consistently high quality cut.

The incorporated VR technology allows automatic setting of the cutting angle and cutting slot and is suitable for cutting both thin and thick sheets of materials, in various types.

Bystronic also demonstrated various software programs including the new ByVision and the successful BySoft.

Both the laser systems and waterjet machine on show will be controlled by ByVision.

Visitors were able to learn more about the software available by participating in the software forums.

As well as its own products Bystronic UK also supplies, in the UK, the Pullmax range of CNC punching machines and the Virtek LaserQC measuring systems and examples of these were on show.

* CNC punching - flexibility, increased efficiency and the highest level of precision for punching are provided by the latest Pullmax punching machines and the Pullmatic 520 FC is the perfect illustration of this.

Not only does the customer get a punching machine when he invests in this machine he also gets the opportunity of turning it into a press brake, making it possible to finish complex parts in one set-up.

The punching and and profiling machine shown features this new tooling option which has been developed in conjunction with Wilson Tools.

This optional six-station tapping unit allows folds of up to 50mm long x 70mm high to be bent making the machine more versatile and allowing increased profits per part.

The machine is also equipped with a fabrication centre (FC) for the automatic loading and unloading of sheets for lights out or un-supervised operation.

Also to be seen on show was the successful and versatile Virtek Laser QC.

The system provides a unique method of rapidly inspecting 2D parts and reverse engineering and offers customers the opportunity to monitor their process through SPC charts easily generated by the Laser QC software.

Nitrogen generator cuts laser consumption costs

2007-01-13T23:42:00.000-08:00

Subcontractor purchased a nitrogen generator to replace an expensive manifold cylinder pack supply and has had no customer complaints due to edge quality, no breakdowns, or 'gas-outs'.

Martin Cook of Cutting technologies said: 'We purchased a nitrogen generator from MSS in November 2005'. 'We were previously running on MCP's (manifold cylinder packs), the most expensive option of nitrogen supply, but were struggling to get our Landlord's approval for external bulk storage. As an example of the high cost, we had to charge £80.00 per hour just for nitrogen when cutting 12mm stainless.' He explained: 'We only run two lasers, but we run them long and hard and a high percentage of our work is decorative stainless, aluminium and brass, up to 15mm thick in stainless steel, 10mm in aluminium and 6mm in brass.

We are currently running the generator at 90ppm oxygen impurity and achieving a flow-rate in excess of 70m3 per hour.' Prior to purchase the company carried out numerous trials at different ppm oxygen levels and showed the results to the most critical clients.

The company reports that it had had no negative feedback at levels below 150ppm, so proceeded with the installation.

Cook said: 'We chose a generator that would cope with 80% of our work and expected to have to supplement its output occasionally with MCPs.

We have run solely on the generator since November 2005 and have had no customer complaints due to edge quality, no breakdowns, no 'gas-outs' and never had to supplement the generator output with bottled nitrogen.' He added: 'In other words, the generator has done exactly what it 'says on the tin.

The most it has coped with across the two machines has been 10mm stainless on one and 5mm aluminium on the second machine, again with no issues and the generator was filling the tank quicker than we were emptying it.' The company has negotiated a five year maintenance contract, which is next to nothing per month, efficiency has improved dramatically through not having to constantly change MCPs, the factory is a much safer place because as it is not constantly moving the MCPs around and, said Cook: 'We dare not print how much we are saving per month on the nitrogen.

We are really pleased the landlord stopped us installing external bulk storage, he's saved us a fortune.' Nitrogen represents a significant percentage of a laser company's costs and anything a factory can do to reduce this is beneficial to its profitability and its competitiveness against other processes.

Award for metalworking and fabrication machine

2007-01-12T23:41:00.002-08:00

Prima Industrie beat off stiff competition from other leading machine tool manufacturers to win the Best Metal Forming / Fabrication Machine category in this year's Metalworking Production awards.

Prima Industrie beat off stiff competition from several other leading machine tool manufacturers to win the Best metal forming / Fabrication Machine category in this year's Metalworking Production awards, held at the Hilton Birmingham Metropole Hotel on 16th May. The company's new Syncrono machine - exhibited for the first time in the UK on Prima's stand at the MACH '06 show - won the judge's decision on the strength of its innovative design, which dramatically reduces cycle times and piece part production costs. Claimed to be the world's fastest 2D laser cutting machine, the Syncrono achieves a maximum head acceleration of more than 6g, twice that of previous benchmark machines, enabling it to produce over 1000 holes per minute in light gauge sheet metal applications.

Its ability to double the performance of other high speed laser machines is due to a number of key design features.

In effect, the new model is two machines in one - a larger unit with a 3000 x 1500 mm processing area, combined with a compact, short stroke, high dynamic head.

Both elements move independently, but are fully synchronised using patented control algorithms - allowing the machine to achieve extremely high cutting rates throughout a large machining envelope.

The parallel kinematics of the Syncrono's head and main carriage are optimised for minimum cycle times, with the required cutting trajectory generated automatically from standard machine G-code, without the need for any operator intervention.

Through increasing productivity by as much as 50% on components up to 3 mm thick, the Syncrono challenges the speeds of many CNC punch presses, while eliminating the need for costly tooling, cutter refurbishment, setting-up and change-over times.

The new machine's dynamically-balanced, low mass head incorporates advanced control features to eliminate vibration and maximise both machining accuracy and repeatability.

The Syncrono also utilises a high performance Prima CP4000 laser unit and is equipped with interchangeable optics to accommodate materials up to 20 mm thick.

Further features include simple installation and commissioning, constant laser beam length over the complete machining area, fibre-optic linked digital servo drives and intuitive operation using the system's 15 inch flat touch screen interface.

Prima's Syncrono is available with optional laser piercing monitoring for optimising the processing of heavy gauge materials, and a number of automatic work handling solutions for maximising production throughput.

High productivity fabrication with lasers, presses

2007-01-12T23:41:00.001-08:00

As part of a strategy to create a production facility separate to its prototype shop, Coventry-based DCM has opened a new high productivity fabrication centre at Warwick.

As part of a strategy to create a production facility separate to its prototype shop, Coventry-based DCM has opened a new high productivity fabrication centre at Warwick. Forming the centrepiece of the new facility is a Trumpf L2510 flatbed laser and two TrumaBend V500 CNC press brakes, which produce small batch production components on a rapid turnaround Kanban system for a number of high profile automotive OEM and Tier 1 companies. 'We wanted to create a different philosophy at our new site,' explains Managing Director Nigel Stokes, 'one of lean manufacture and Kanban operation - hence the machines we selected were vital to its success.' Although DCM has been a Trumpf user since the early 1980s, the company had a long look at the marketplace before making its final decision.

'We certainly considered others but as always the price/quality ratio of Trumpf won out.' DCM's new Warwick facility opened in January complete with an L2510 flatbed laser and two TrumaBend V500 press brakes.

'Warwick is now our production centre,' continues Mr Stokes.

'All 14 staff at this facility are new recruits as we wanted to start with an open approach to the new methodology we were looking to impart.' Operating for automotive customers, as well as other clients in the aerospace, telecommunications and construction sectors, means DCM has had to gear up for Kanban deliveries.

The company's prestigious clients supply an empty storage box to DCM once a week to be filled with components of the correct quality and quantity.

Batch sizes are typically in the region of 25-50 a week - the largest batch is around 200.

DCM processes parts ranging in thickness from 0.9 to 10mm, mostly from mild steel material.

'We have designed the whole process to be ultra lean,' says Mr Stokes, 'which means having flexible machines that can be set-up as quickly as possible - one of the key reasons we selected Trumpf.

The L2510 laser has a self-loader, which is one of the best purchases we have ever made - automation is absolutely crucial to compete with manufacturers based overseas in economies with a low cost base.' Formed nearly 50 years ago, DCM continues to be a leader in its field.

The company's headquarters remain at Coventry, where 70 staff are based, although the facility only produces prototypes since the opening of the Warwick scheduled production centre.

Mr Stokes says that it is the balance of quality, flexibility and price that sets DCM apart from its competitors, as well as one other key factor: process repeatability.

'When we load a program and press the start button we need to feel confident that the part will come off correct - we get that with Trumpf.'

Plasma cutting range with high cutting speeds

2007-01-11T23:40:00.001-08:00

The most recent addition to ESAB Automation's plasma cutting range is the Suprarex SXE-P.

The most recent addition to ESAB Automation's plasma cutting range is the Suprarex SXE-P. It delivers high cuttings speeds, low running costs and requires minimum service. It combines a rugged heavy duty portal beam and rail system with extremely precise, maintenance free, dynamic AC drives and guiding systems.

Advanced, easy to use CNC controls with colour graphics are also included.

The Suprarex SXE-P can be supplied with a variety of precision plasma systems for cutting and marking to cover plate thicknesses from 1 mm to 40 mm.

The performance of the Suprarex SXE-P is further enhanced by high cutting and positional accuracy.

This is achieved through the double side rack and pinion longitudinal drive and rack and pinion transverse drive with optional linear guide.

The CNC cutting database control is intelligent and easy to use.

Collision protection on plasma torch is provided to avoid damage and there is also enhanced collision protection.

Cutting and positioning can be carried out at 24000 m/min.

Optional cutting tools including additional plasma and oxy-propane torches as well as optional plasma bevel cutting.

High precision laser profiles medical implants

2007-01-11T23:40:00.000-08:00

High precision laser cutting system profiles medical implants such as stents or other precision components and speeds are ten times higher than with the first machines.

Rofin / Baasel Lasertech presents the new StarCut Tube - a high precision laser cutting system for profiling medical implants such as stents or other precision components. State-of-the-art technology allows cutting a coronary stent of 8mm length in less than 1 min. A stent is a device which is surgically inserted into blood- or air-ways and expanded to hold a passage open to facilitate free flow.

Coronary stents are typically of order of 1mm diameter metal tubes which are inserted inside arteries as an alternative to heart bypass operations, for example.

Over 10 years ago the first such tube cutters were sold for making stents.

These had a gear driven rotary axis, an open work station and a separate supply unit for the laser source.

Today, after several hundred successfully installed systems, the fifth generation of StarCut Tube operates at up to ten times faster than the original launch machine.

The basis for the enormous increase in productivity is the state-of-the-art motion system based on linear motor technology and the direct drive rotary axis.

The sophisticated control unit of the laser adjusts all performance parameters of the laser source optimally to the travel speed of the motion system.

Even smallest radii pose no problem.

The actual contour trajectory can be viewed on the large TFT monitor at any time.

With the proven massive granite set-up, a dimansional tolerance of only a few microns can be achieved - and with high long term stability.

Another benefit the new StarCut Tube offers is the possibility to choose between several available sources: the proven StarCut 18 laser with a power range of 7 to 25W achieves 'kerf' (the width of the laser cut) widths of 18-20 microns.

The new StarCut12fm, a fundamental mode laser with 12 W makes kerf widths smaller than 15 micron.

Finally, state-of-the-art fiber laser technology: the Star-Cut Tube Fiber with maximum 20W power can also achieve kerf widths below 15 micron in suitable materials with high productivity.

Laser source, control, drives with supply modules and the automatic tube loading are integrated into the compact and ergonomic housing.

Rofin/Baasel Lasertech paid particular attention to ensuring easy access to the components, for set up, loaning and unloading.

Operation and the loading and unloading of tubes is done from the side.

A high quality stereo microscope or, as an option, a camera allows process viewing.

The StarCut Tube is configured to use a variety of process gases with a pressure of up to 25 bar.

The StarCut Tube wet cutting option allows cutting with liquid flushing inside the tube.

The optional 4-axis version allows non-radial cuts which opens up the possibility of cutting hole contours as produced by mechanical milling or eroding.

In this way novel geometries can be created to optimize the flexibility of stents even further.

For cutting of high precision flat sheet components, a cutting support box is available.

Waterjet cutting on show with intensifier

2007-01-10T02:52:00.001-08:00

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS), 10 a.m.-6 p.m., Sept 6-13, at McCormick Place in Chicago.

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS), 10 a.m.-6 p.m., Sept 6-13, at McCormick Place in Chicago. During IMTS, Jet Edge sales engineers will conduct live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System utilizing the high-powered iP60-60 intensifier pump, AquaVision Di motion controller, and the new digital readout for Multi Head Positioning. Look for Jet Edge in booth #B-6252.

Jet Edge's waterjet-cutting systems cut nearly any material, from food products to hardened tool steel to titanium.

The company's systems are being used by the world's leading airlines, automotive and aerospace manufacturers as well as industrial manufacturing companies and machine and job shops around the world.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

'Our cutting systems have many advantages,' said David Dumas, Jet Edge sales director.

'We are known for our very large work areas and accuracy.

We can hold an accuracy of 0.005 inch with a repeatability of 0.001 inch over the entire work envelope.

Our cutting systems are powered by hydraulic intensifier pumps that can offer 15,000 to 30,000-plus hours of operation on the hydraulic pump, depending on the model.

This, of course, means greater productivity and lower operating costs.

The cutting systems are controlled by a state-of-the-art AquaVision Di motion controller that guides users through the project step-by-step.' During IMTS, show participants can see for themselves the remarkable versatility and speed of Jet Edge's High Rail Gantry System.

They also can see Jet Edge's new iP60-50 intensifier pump in action.

The 'heart and soul' of the Jet Edge waterjet cutting system, the iP60-50 intensifier pump is rated for 60,000 psi and features an extended-life hydraulic system.

The iP60-50 intensifier pump provides easy access for all service and maintenance.

It features non-threaded high-pressure components in the high-pressure cylinder, an improved performance check valve, and low torque values.

The Jet Edge iP60-50 intensifier pump leads the industry with ease of operation and low operating cost.

It requires very few tools to maintain.

The cutting system is controlled by the AquaVision Di motion controller that guides users through the process from job set-up to production.

With the AquaVision Di, single parts, part arrays, mirroring, scaling, rotation, and plate alignment are right at users' fingertips.

The AquaVision Di is fully networkable, allowing part programs to be generated offline and easily transferred to the system's hard drive for production.

Feed rate and acceleration are automatically varied, based on known features of a specific job.

Dynamic tool offset, or 'cutter compensation,' is employed real-time, and an optional real-time pump control allows remote starting and stopping of the pump, dual pressure set points for piercing hard-to-pierce materials, and unlimited data logging of every process parameter imaginable.

The AquaVision Di includes a full-featured hand-held pendant that allows feed rate override, return-to-path, program zero set points, and XYZ axis control.

Show participants are sure to be impressed by Jet Edge's new Digital Readout for Multi Head Positioning, which improves productivity by reducing setup time.

The Digital Readout for Multi Head Positioning digitally displays cutting head positions, eliminating manual measurement.

It is an excellent addition to your Jet Edge waterjet cutting system.

Intensifier expands water jet cutting capability

2007-01-10T02:51:00.001-08:00

Supplier of composite components to the Formula One and motor racing industries has expanded its waterjet cutting service by adding a 50HP intensifier to an existing cutting table.

For the highly competitive Formula One and motor racing industries, the delivery of critical components and assemblies on time, every time is absolutely critical. Panther Composites' waterjet cutting division is a major supplier to this market and has now upgraded its waterjet cutting service by adding a new KMT Waterjet Cutting Systems Streamline Classic 50HP intensifier to its existing Powerjet Systems cutting table. This installation is already paying dividends with the company now able to take on more and varied cutting tasks from both the motor racing sector and other general sub-contract engineering customers.

Panther Composites was originally founded by a management team with extensive Formula One engineering experience with the Williams team.

When Paul Bowen joined the company to establish the waterjet cutting services division over two years ago, he too had a wealth of experience in the motor racing sector.

'There is no leeway for lateness on delivery to customers in this sector and the ability to be able to cut a variety of materials is also critical,' he said.

To provide the type of service required, Panther invested in a Powerjet Cutting Systems 3.0m x 1.5m waterjet cutting table.

In the last two years this has provided Panther with excellent service.

For its many different customers involved in motor racing, Panther uses the abrasive waterjet cutting process to cut materials as tough and varied as aluminium, titanium, Inconel, tungsten as well as rubber components.

'There is no material that our customers need that we cannot cut,' said Bowen.

The decision to invest in 2005 in a new KMT Waterjet Systems Streamline Classic 50HP intensifier and Abrasive Management System to use alongside the Powerjet Systems cutting table was made in order to give the company even greater opportunities to provide services both to the motor racing and general engineering sub-contract services sector.

'We now have a world class waterjet cutting facility, combining the Powerjet table with the KMT intensifier,' said Bowen.

The investment has given Panther Composites the ability to take on extra work with confidence, including the cutting of heavier materials.

The company's customer base now also includes building industry clients where the ability to cut ceramics and stone with high accuracy is important.

The 37kW Classic pump has represented a highly cost-effective investment for Panther and includes advanced features such as Soft Start which can give up to 20% energy savings when the pump is first switched on.

The Hard Seal End Cap topwork design reduces both consumable costs and downtime.

The AMS I Abrasive Management System is helping to automate the cutting process.

It starts with the Abraline III abrasive transfer system that monitors abrasive availability and ensures sufficient quantities throughout the cutting process.

The Feedline III abrasive metering system accurately controls the flow rate of abrasive to the Autoline abrasive cutting head which gives a consistently high quality of cut.

Off-line programming for cutting any components helps to speed Panther's production process with cutting programmes downloaded directly to the Powerjet Systems cutting table.

Bowen concluded, 'There is no question that the waterjet cutting process is highly versatile and has opened the door to new customers for Panther Composites.

The KMT installation is proving highly reliable and efficient.

In combination with the Powerjet Systems cutting table, it is allowing us to give out customers a first class sub-contract service.'

Off-line CAD/CAM simplifies nesting/cutting

2007-01-09T02:50:00.001-08:00

A powerful off-line drawing, editing and nesting software for CNC profiling machines allows drawing, nesting and cutting operations to be performed quickly off-line, without fuss.

ESAB Automation's new powerful off-line drawing, editing and nesting software for CNC Profiling machines is ideal for all sizes of fabricators. It allows drawing, nesting and cutting operations to be performed quickly off-line, without fuss. Interactive nesting for improved plate utilisation is offered together with cutter path definition, marking tool definition and post processing for all CNC controls.

Using this software, the operator can develop just about anything for plate and sheet fabrication including 2D + 3D DXF and marking, forming and costing details.

The software also offers a range of productivity options.

The profile quoter defines shape, specifies plate/process details, nests and calculates the cost.

The scanned outline facility converts scanned images into vectored outlines ready to cut.

It supports BMP, TIF and other formats and can output DXF and CAM files.

The font generator turns windows text into NC code, whilst the 3D development option ensures fast and simple plate development.

Other options include a remnant plate tracer which is a unique graphic remnant tracing software.

It is very simple to operate either standalone or as part of an integrated system.

The automatic nesting feature maximises plate usage, optimises machine time and minimises programming time.

CNC flatbed laser needs minimal supervision

2007-01-09T02:50:00.000-08:00

Sheet metal working subcontractor has replaced a CNC punching machine with a flat bed laser, resulting in in 24h of minimally supervised work against a former 8h of manned production.

A UK subcontract manufacturer, Saint Ann's Sheet Metal Company, is replacing an existing punching machine with a new Trumpf Trumatic L2510 flatbed laser and in so doing swapping 8h of manned production for 24h of minimally supervised and 'lights out' production. 'The growth potential this machine offers us is huge,' explained managing director Dave Bloomer as he confirmed the company's order at MACH 2006. 'But it is not just productivity of the machine that is important to us, it is also the superb quality of its output.' Saint Ann's is taking delivery of the L2510 that appeared on the Trumpf stand at the show, a machine that attracted considerable interest thanks to its built-in automation.

'Nothing compares with the L2510 for its small footprint,' Bloomer added.

'Our factory is in a residential area and space is limited.

Being able to get significantly greater productivity from such a compact machine is great for us.

Our location also requires us to keep close control of our noise levels and the laser will certainly help to create better neighbour relations.' The L2510 is Saint Ann's first Trumpf machine and an important reason for its choice is to eliminate the need for deburring.

The majority of work produced on its existing punching machines needs secondary finishing, a time-consuming and costly addition.

With customers seeking significantly shorter lead times and competitive costs, methods need to be continually improving these days.

An existing job for 20,000 parts per annum for the electronics industry will immediately benefit from the new acquisition.

'We will make substantial productivity gains as the L2510 will take cycle times down by 10 seconds per part,' Bloomer continued.

'And of course there will be no need to deburr.' The company also cites Trumpf's Telepresence as an important feature in minimising potential downtime through on-line problem diagnosis.

As well as being able to provide a better service to its established automotive, shop fitting, H and V and marine engineering markets Saint Ann's is confident that the L2510 will greatly extend its scope.

'This is a highly flexible machine that will also allow us to include working with tube as part of our services,' Bloomer concluded.

'Installation started on 24th May and we are expecting great things from this machine.

We have an excellent team of men at Saint Ann's and I am positive that they will make very good use of this super laser to take the company to its next phase.'

2D laser system machines tube and box sections

2007-01-08T02:49:00.000-08:00

The addition of a 2D system with a flatbed laser will enable a subcontract fabricator to undertake the machining of tube, profiles and box sections - for which demand in the UK is increasing.

From its origins as the provider of laser cutting services to other companies in the WEC Group, Laser Engineering has emerged as a major player in the laser- subcontracting field. Its impressive growth has been secured by continued investment in the latest technology but the company's latest acquisition will do more than simply increase capacity. Laser Engineering has just ordered a Trumatic L3050 flatbed laser machine from Trumpf with its sights firmly set on adding tube and box section cutting to its portfolio of services.

The machine is equipped with a Rotalas system, consisting of a NC rotary axis fixed to the machine frame for machining pipes and profiles.

A flexible support system guarantees that a wide variety of tube is guided securely.

The WEC Group now comprises four separate and complementary divisions - WEC providing camera-mounting solutions, welding engineering, architectural fabricator M-TEC and Laser Engineering.

It employs around 200 people.

The divisions serve all manufacturing industries from automotive, construction and transport through to pharmaceutical and catering, covering the full spectrum of heavy to light fabrication work.

Laser Engineering already has three Trumpf flatbed laser machines with 4, 5 and 6kW power with a bed size up to 4m x 2m.

They allow the processing of aluminium, mild and stainless steel from 0.5mm to 25mm.

Despite being a long term Trumpf customer however, Laser Engineering did not automatically 'plump' for another Trumatic.

The company wanted to assess thoroughly all other options to ensure it had the best machine for its needs in relation to both cost and performance.

In the final analysis however it was the Trumpf L3050 that met all Laser Engineering's purchasing criteria.

This latest addition to its range will have the same capacity as the existing Trumpf flatbeds but will be equipped with a series of optional features to increase its capability.

The addition of RotoLas in particular will enable Laser Engineering to undertake the machining of tube, profiles and box sections.

The demand for this type of work is indeed on the ascendancy and the company wanted to ensure that it was able to anticipate its customers' needs in this regard.

'We operate very tight lead times and needed the L3050 to guarantee fast turn round of our increasing workload,' explained general manager Wayne Wild.

'For us the L3050 offered the quality we needed at a price and with running costs that would prove most economical over a five year period.' Laser Engineering's new L3050 is due for installation at the company's factory in Darwen, Lancashire, UK, during the summer.

'Its extra capacity will enhance our Gold Same Day and Silver Next Day services,' Wild concluded.

Waterjet cutting eliminates batchwork tooling

2007-01-08T02:48:00.000-08:00

A versatile water jet cutting machine has helped a gasket manufacturer increase productivity by eliminating the need for tooling for short and long-term jobs and prototypes.

During economic downturns, many businesses rein in their spending and hope merely to stay afloat until the storm passes. Others seize the opportunity to lunge ahead of their retreating competition by reinvesting in their business and increasing their productivity. This is a story of a gutsy gasket company that never stopped investing in its business and continues to grow as a result of its bold initiative.

Located in historic Haverhill, Massachusetts, New England, USA, Die Cutting is a rapidly growing gasket fabricator that serves the military, electronics, medical, and commercial industries.

With capabilities including die cutting, laser cutting, waterjet cutting and CNC drilling and routing of plastics, NEDC manufactures products from a wide range of materials, including elastomer, sponge, foams, films, extrusions, EMI shielding and thermal interface materials.

Business has been very good for this ISO 9001:2000-certified company, which is quickly transitioning from a small job shop to a true manufacturer.

In fact, NEDC recently moved into a new 18,000ft2 building, a huge step forward from its humble beginnings in 1982, when husband and wife David and Kim Abare opened the business at a former shoe factory on Haverhill's River Street.

In March 2005, NEDC received its 'Woman Owned' certification from the Women's Business Enterprise National Council, an important accomplishment for a company whose primary clients are defense contractors who are asked to place 23% of their dollars with certain small business categories.

In May 2005, NEDC received a US$40,000 grant from the Commonwealth of Massachusetts' Work Force Training Fund to implement lean manufacturing, and in spring 2006, the company received its Small Business Association 8(a) certification.

Over the years, NEDC has developed premier partnerships with Parker Chomerics, Laird, Thermagon, MTI, Grondyke, Bergquist, 3M, St.

Gobain and Rogers.

NEDC president Kim Abare attributes her company's phenomenal growth to continued reinvestment in the business despite economic downturns.

'Most companies feel a temptation to stop spending on advertising, marketing and new equipment when the economy takes a downturn,' Abare stated in the October 2005 'Gateway' magazine.

'You must always keep reinvesting in the business in order to stay ahead of the competition.' Despite its growth, NEDC retains the hospitality of a family-owned business.

NEDC's staff of 28 provides the quality products and service you would expect in this enterprising New England river town.

During the past two years, NEDC has made a number of its own enterprising moves, including adding abrasive waterjet cutting services to its lengthy list of capabilities.

In 2004, NEDC acquired a Jet Edge abrasive waterjet cutting system, which it uses to cut numerous types of material including metal, plastic, rubber, resin composites, tile, and glass.

Manufactured by Jet Edge, of St.

Michael, Minnesota, the abrasive waterjet system can cut through any material utilizing water that is pressurized up to 55,000 lb/in2 with a Jet Edge intensifier pump.

Abrasive garnet is added to the water to increase cutting speed through hard materials.

NEDC's Jet Edge system is capable of cutting sheets that are as big as 5ft by 10ft.

The machine is powered by Jet Edge's 50HP 55-50C intensifier pump and controlled by Jet Edge's PC-based AquaVision interface featuring SigmaNest software and automated features including 'Automatic Trueshape Nesting', 'Automatic Feedrate' generation and corner ramping, graphical and/or G and M code display, plate alignment, remote pendant, real-time cutter compensation, point and click start/stop points and more.

NEDC could have bought their waterjet system from a number of manufacturers, but they chose Jet Edge primarily because it is American made, Kim Abare said.

'We have lost so much business overseas, that to us, it is paramount that we invest in American-made equipment,' she explained.

'Beyond this reason, Jet Edge's sales director David Dumas specifically flew out to our facility, 1,500 miles away, to ask for our business, making us feel like we are an important customer.' NEDC vice president David Abare said he has been very satisfied with Jet Edge's equipment and customer service.

'First and foremost, compared to other equipment, it almost never goes down,' David Abare said.

'It is the most reliable piece of equipment we've ever invested in.

It's a versatile machine, meaning that it can cut anything, anyway, anytime.

By far, Jet Edge has done everything they said they would.

Their service has been fabulous.

Their sales guy is welcome here, and stops in from time-to-time, buying pizza for our shop.' The Jet Edge waterjet cutting system has helped NEDC increase productivity by eliminating the need for tooling for short and long-term jobs and prototypes, he noted.

'The part can be cut instantly using a DXF/IGES,' he said.

'We have one customer that requested an intricate part that would have cost US$8,000 to tool.' 'We were able to save that customer that money and cut a prototype, allowing him to make additional changes.' In addition to saving production time, the Jet Edge system also saves NEDC material costs by giving them the ability to tightly nest parts, David Abare noted.

Asked if he would recommend Jet Edge to other businesses, David Abare responded: 'Absolutely.' * About New England Die Cutting - call 001 978-374-0789, visit http://www.nedc.com or e-mail sales@nedc.com.

* About Jet Edge - Jet Edge is a global designer and manufacturer of ultra-high pressure waterjet systems for precision cutting, surface preparation, coating removal, and hydro demolition.

Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

* Advantages of Jet Edge Waterjets - Jet Edge waterjets offer many productivity and flexibility advantages over traditional cutting methods including: no sharpening and no burrs requiring secondary finishing.

Waterjets completely eliminate heat-affected zones, toxic fumes, recast layers, work hardening, and thermal stress, and offer a hygienic method for cutting food.

Jet Edge waterjets can hold a positional accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope.

They have been known to cut materials up to 15in thick.

Waterjets are environmentally friendly and produce no hazardous waste, reducing waste disposal costs.

They can cut off large pieces of reusable scrap material that might have been lost using traditional cutting methods, parts can be closely nested to maximize material use, and the waterjet saves material by creating very little kerf.

Waterjets use very little water (a half gallon to approximately one gallon per minute depending on cutting head orifice size), and the water that is used can be recycled using a closed-looped system.

Waste water usually is clean enough to filter and dispose of down a drain.

The garnet abrasive is a non-toxic natural substance that can be recycled for repeated use.

Garnet usually can be disposed of in a landfill.

Portal cutting machine is compact, low-cost

2007-01-07T02:48:00.000-08:00

A low cost, compact portal cutting machine will appeal to small and medium sized companies looking for a competitively priced cutting system that optimises quality, productivity and efficiency.

ESAB Automation has introduced the new Falcon low cost, compact portal cutting machine. It will appeal to small and medium sized companies looking for a competitively priced cutting solution that optimises quality, productivity and efficiency of production. The standard Falcon is an oxy-fuel cutting machine package with two torches.

It is also possible to up-grade to plasma-arc or indeed a combination of plasma-arc and oxy-fuel gas cutting.

Each cutting torch has automatic height adjustment to ensure that the cutting torch head is always at the correct distance from the workpiece.

The Falcon can be used to cut on all steels, aluminium and alloyed steels.

Depending on the torch used, metals up to a maximum thickness of 150mm can be cut.

The cutting width is 2.70m, the maximum cutting length 15m.

Fire-damaged CNC laser profiler serviced in days

2007-01-07T02:46:00.000-08:00

Following a serious fire, a CNC laser profiling machine company ordered a replacement laser resonator from Germany for a damaged, resited machine, and it was installed by next day.

On the face of it the loss of its manufacturing facility in the UK's Buncefield Oil Depot blaze in December 2005 could have been completely ruinous for subcontractor PCD. However with the support of suppliers, fellow traders and its insurer, PCD was up and running again within a matter of days. Furthermore, the disaster has given the company the opportunity to review its business and to re-establish itself with a greater range of manufacturing services in purpose designed premises.

Although its building was deemed unsafe after the blast PCD was fortunate not to suffer significant equipment loss.

Its powder-coating line and a graining and deburring machine were irreparable as was the laser resonator on a machine that is central to its production, the Trumpf L2530 flatbed laser.

Otherwise everything remained operable and in the immediate aftermath the PCD team simply donned hard hats and continued manufacturing as best they could.

Thanks to the swift work of insurers however PCD soon found temporary accommodation in the old Aquascutum factory in Hemel Hempstead.

Within a matter of days the company had re-located the lion's share of its production facility.

In addition to its Trumpf flatbed, PCD also has two Trumatic punching machines and chairman, Phil Cutts is quick to commend Trumpf's speed and efficiency in getting these important machines up and running again.

He explained, 'Having installed the L2530 at the new site Trumpf ordered a replacement laser resonator from Germany at 3.30pm the same afternoon.

When I arrived at the factory at 8.30am the following day it was already on the machine.

Trumpf really did us proud.' Within weeks a new powder coating line had been ordered and installation completed by April '06.

The grainer was ordered, installed and is now fully operational.

'By comparison with last year's trading figures in February '06 we were at 65% and by March, 80%,' explained David Stoneham, managing director.

'And by April we expect to resume the monthly business growth that prevailed before the fire.

Everyone has worked extremely hard to secure this recovery.' PCD is a BS EN ISO 9001:2000 certified subcontractor specialising in precision sheet metalwork, finishing and assembly.

It serves a wide customer base encompassing the telecoms, datacoms, audio, electronic and lighting industries.

During its 24-year history the company has steadily grown, introducing additional services such as powder coating and silk screening.

The original factory, destroyed by the blast, reflected this organic growth.

Although a devastating experience, the fire has presented PCD with the opportunity to plan a new factory layout that really is fit-for-purpose with flexibility for expansion.

Furthermore, it has allowed Phil Cutts and his team to look at the business and make it even better.

'We have invested in flexible, automated processes to enable us to undertake a broad variety of work economically,' Cutts explained.

The Trumpf TC5000R is equipped with automatic loading and the software is installed on PCD's latest acquisition, the TC3000R to provide a similar degree of automation.

'We are running both lights-out with minimal manning, specialising in close limit work such as chassis, panel work and enclosures.' PCD sees an expanding need for this type of cost-conscious, quality manufacturing and is now seeking to add value to the business by augmenting its growing sheet metalworking operation with other in-house machining services.

'Currently we outsource any machining element a job may require,' added Cutts.

'Having turning and milling in-house will allow us to provide customers with the complete manufacturing package and give us full control of scheduling and quality.' Plans for PCD's new factory on the original site have now been finalised.

High speed routers machine car bodies

2007-01-06T23:48:00.000-08:00

Four high cutting speed routing systems are producing interior components for a sports car manufacturer by triming edges and forming holes and slots in a wide range of polymeric materials.

At the company's plant at Boetzingen in South-West Germany, Peguform is using an installation of four routing systems from KMT Cutting Systems to produce interior components for a Stuttgart-based sports car manufacturer. Routing is the preferred finishing technology for the dashboards, door panels and central consoles that Peguform produces in a state-of-the-art facility that brings together slush moulding, injection moulding, foaming and a range of finishing technologies on the same site. Routing is a dry cut process that utilises an electrically powered routing head with a spindle-mounted bit, which is spun at very high speeds up to 50,000 rev/min to trim edges and form holes and slots in a wide range of polymeric materials.

The method gives a very accurate material separation and produces a high quality cut edge.

Routing can also be used to cut materials to a pre-defined depth which is key to the use of routing in making perforations for air bags.

Of the four KMT routing systems at Peguform, two are dedicated to finishing left and right drive dashboards, two are dedicated to work on driver and passenger side door panels and the fifth is used to rout the central console parts, respectively.

Each of the systems is a self-contained unit meeting all EC machinery safety standards, housed in a low footprint enclosure separating the routing process from the operator and the rest of the plant.

The systems have fixtures mounted vertically on a double sided flip-frame, allowing the operator to unload and load a new part, whilst another is being routed on the flipside inside the enclosure, increasing system productivity.

At the front of the routing enclosure, there is a rolling door which acts as a protection system for the flip frame.

In addition, there is a horizontal light barrier as back-up protection between the rolling door and the flip frame.

The vertical design of the fixture on the flip-frame offers excellent ergonomics for loading parts.

The part is fixed in place by a combination of clamping and vacuum suction.

Sensors mounted on the fixture detect the presence of the part and whether or not it is properly positioned before the routing cycle can begin.

On the dashboard fixtures, there are dedicated sensors feeding the system with measurements of the position of the airbag section, whilst for the door panels, there are sensors to detect whether or not the correct inserts are in place for the side air bag systems.

The routing systems at Peguform are equipped with many of the options available from KMT.

The first of these is a Fixture change unit with which just one operator can change the fixture on the routing systems in under three minutes.

It is an easy system to use that also provides secure and space-saving storage for the fixtures when they are not being used.

Another of the options is a barcode reader that reads the barcode on the part to confirm its identity.

This is then checked through a production control interface also supplied by KMT, which talks to the plant's manufacturing database to ensure that the part on the fixture is approved for routing.

If the database indicates there is a fault, then the routing system is instructed to destroy the part.

As well as overseeing the process, the production control interface also saves a full record, comprising some 85 different parameters, of all activity in the routing boxes to a process data system for download to the manufacturing database.

Normally the part is passed for routing, the rolling door is lowered and the cycle is started from a control panel located outside the box.

When the part is flipped inside the box, it is marked securely with its part number using an optional laser marking system.

The KMT routing stations feature a single IRB 2400/16 M2000 industrial robot from ABB offering a 16kg handling capacity and 0.06mm positional repeatability.

Inside the Box, the 400 lux lighting provides excellent illumination for programming the robot.

The system utilises the renowned Jaeger range of spindles providing high quality performance for this exacting application.

The routing boxes are equipped with tool change stations, allowing tools to be changed while the routing system is in operation.

The optional tool change stations also offer an automatic update of tool parameters through a tool length measuring system that provides an accurate length for each tool in the system.

When installing a new tool on the tool change station, the length is compared to a nominal value and any variance is taken into account when the tool is later used in the routing process, ensuring very high accuracy after each tool change.

The measurement system is also utilised to gauge whether or not there has been a break in the tool, performing measurements at programmed intervals and alerting the system if a tool break occurs.

The system automatically measures a tool after change to ensure that a tool of the right length is loaded, hence avoiding any crash in the system.

The numbers of cycles a tool should be used before it needs to be changed can be programmed into the system to remove the risk to the routing process and the quality of the parts it produces.

The tool change station also includes a Renishaw 3D sensor - system that is used to take 3D measurements in three corners of the air bag system to ensure that the perforations produced by the routing head for the air bag are to the correct tolerances.

As well as good ergonomics, another advantage of the vertical worktable arrangement is that waste material falls by gravity on to a conveyor below the routing area, from where it is transported out of the box into a waste hopper.

In addition, the airborne dust that always accompanies routing is sucked through ducts either side of the worktable, by a high powered air cleaning/filter system that passes the air through filters, before returning the filtered air through floor level vents at the back of the system.

As demonstrated by the systems at Peguform, the routing range from KMT Cutting Systems ensures high position accuracy for the router with very efficient waste disposal.

The systems have a small footprint and are easy to install.

In fact, the systems offer a 'Plug and Produce' capability, allowing them to be started up in just one day, if KMT supplies the fixtures and cutting programs from the beginning.

All the routing systems come with a global support package second to none, providing technical, service and parts coverage in virtually every country in the world.

Linear motors power water jet profilers

2007-01-06T23:47:00.000-08:00

Applying linear motors to the X-axis movement of each cutting head can allows accurate control by the CNC with a positioning accuracy as fine as 0.05mm using coils fitted to each head.

Water Jet Sweden is believed to be the first manufacturer of waterjet cutting machines to incorporate linear drives in this technology for customers who have discerned the technical advantages of this option. Increasingly already being applied to advanced machine tool designs, linear drive systems are now being taken up by designers of other types of machinery and equipment used in a variety of manufacturing processes throughout the world. In the case of Water Jet Sweden, the close collaboration enjoyed between themselves and CNC suppliers GE Fanuc over recent years has seen the introduction of a linear drive option across the range of profilers produced at the busy Ronneby factory in southern Sweden.

With the entire linear drive system being sourced from the same supplier as the other drives systems on the machine, plus the CNC control, the whole package is totally integrated and thereby offers assured reliability.

* Great accuracy - when applied to a Water Jet Sweden machine, the whole X-axis is fitted with a single flat magnetic plate.

The X-axis movement of each cutting head can then be accurately controlled by the CNC with a positioning accuracy as fine as 0.05mm by means of coils fitted to each head.

Lennart Svensson, managing director of Water Jet Sweden, said: 'As well as the well-known advantages of such a drive system, it is especially useful for multi-head profiling.' He cited the many cases where nested items need to be cut using the 'common line' method whereby the intermediate heads of a multi-head arrangement are cutting a line that forms both an 'inside edge' of one component and the 'outside edge' of its companion, thereby simultaneously eliminating the wasteful 'picture frame skeleton' left in the sheet.

Significantly, because each of the heads can be easily re-positioned independently, it is far quicker to replace any one or more nozzles as wear takes place.

This nozzle wear can be compensated for automatically which is an attractive time-saving proposition in a busy shop.

* Other advantages Such drive systems cannot be affected by that small element of component wear that might occur over long periods of time with other drive systems.

Additionally, there are no backlash or pitch error problems to worry about.

The improved long-term positioning accuracies achievable are an added incentive to adopt the linear approach.

The application of a linear drive system to a waterjet profiler is a good one because, unlike other metal cutting machines, there is no swarf or coolant present that might pose a risk to lifelong performance.

In any case, the X-axis drive is mounted on top of the cross gantry where it is well above the work interface.

It is, therefore, in the field of multi-head, high-volume work that the linear drive option can really prove its worth, especially when the added advantages of increased positioning speed and acceleration while profiling are taken into account.

Guide advises on gas cutting machine refurbishment

2007-01-05T23:47:00.001-08:00

A guide to the specification of refurbished profile cutting machines describes a refurbishment and retrofit service for any old ESAB, BOC or Hancock gas cutting machines in use.

A guide to the specification of refurbished profile cutting machines has been published by ESAB Automation, the UK's most experienced and established supplier of refurbished machines. Offering a cost effective alternative to investment in a new cutting machine, ESAB Automation has a wide and continuously changing stock of refurbished machines to suit all types of production requirements. Traditionally, the company offers customers a full refurbishment and retrofit service for any old ESAB, BOC or Hancock branded gas cutting machines still in use.

When companies opt to have their own machines refurbished, they can frequently be immediately swapped with an already upgraded machine of similar specification, saving downtime.

All the critical components of refurbished machines available from ESAB Automation's stock have been renewed to enhance performance, safety and accuracy.

All mechanical bearings, control panels, co-ordinate drive mechanisms, cutters, posts and gas hoses are replaced and optical tracing systems are frequently upgraded to include a new control system.

Retrofit of a CNC control gives customers immediate advantages at low initial cost.

Full details of ESAB Automation's Refurbished Cutting Machine Service are available in the 'New Guide to Refurbished Cutting Machines'.

Waterjet intensifier helps cut coving accurately

2007-01-05T23:46:00.001-08:00

A high performance plasterboard cutter uses high pressure waterjet cutting and linear drive mechanisms to cut lengths of coving with high accuracy and minimal waste.

A world leader in the manufacture and supply of specialised machinery for the worldwide plasterboard cutting industry has come to rely upon waterjet intensifier technology from KMT Waterjet Systems. One of the most recent orders secured by Electronic Control Specialists (ECS) of Heanor, Derbyshire was for its Cove Cutter, destined for a major Australian customer. This high performance cutter uses high pressure waterjet cutting and linear drive mechanisms to cut lengths of coving with high accuracy, which is better than +/-1.5mm, and minimal waste.

The Cove Cutter can achieve line speeds of 85m/min with coving lengths between 1200mm and 16000mm.

For ECS, achieving these performance levels are the result of a combination of the company's own 25 year design experience in plasterboard cutting technology and the advantages achieved by the waterjet cutting process.

Waterjet cutting relies heavily upon the performance of the intensifiers and for managing director Adrian Anthony, KMT Waterjet Systems have always provided the best product: Over the years, ECS has specified KMT (and previously Ingersoll Rand equipment) for many of its specialist plasterboard cutting systems.

'We specify KMT because their intensifiers are of the highest quality, totally reliable and quiet in operation.

The company provides good service back up and we are kept fully informed of product developments and enhancements,' said Anthony.

For the Cove Cutter destined for Australia, ECS specified a KMT Streamline 15HP pump.

This provides the required water pressure to achieve clean, accurate cuts with no noise, waste or dust.

For the customer, this means minimal material wastage and no need for post production trimming operating - resulting in large potential cost savings.

KMT Waterjet Systems' intensifiers are used in a wide a range of general engineering and specialist applications, for many different materials.

ECS recognises that KMT Waterjet Systems' products provide a level of performance for specialist plasterboard cutting machinery not obtainable from inferior, alternative suppliers' products.

Gantry water jet system uses high energy pump

2007-01-04T23:46:00.000-08:00

Live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System demonstrate a high-powered intensifier pump, motion controller, and a new digital readout for multi head positioning.

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS) at McCormick Place in Chicago. During IMTS, Jet Edge sales engineers will conduct live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System utilizing the high-powered iP60-60 intensifier pump, AquaVision Di motion controller, and the new digital readout for Multi Head Positioning. Jet Edge's waterjet-cutting systems cut nearly any material, from food products to hardened tool steel to titanium.

The company's systems are being used by the world's leading airlines, automotive and aerospace manufacturers as well as industrial manufacturing companies and machine and job shops around the world.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

'Our cutting systems have many advantages,' said David Dumas, Jet Edge sales director.

'We are known for our very large work areas and accuracy.

We can hold an accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope'.

'Our cutting systems are powered by hydraulic intensifier pumps that can offer 15,000 to 30,000-plus hours of operation on the hydraulic pump, depending on the model.

This, of course, means greater productivity and lower operating costs.

The cutting systems are controlled by a state-of-the-art AquaVision Di motion controller that guides users through the project step-by-step.' During IMTS, show participants can see for themselves the remarkable versatility and speed of Jet Edge's High Rail Gantry System.

They also can see Jet Edge's new iP60-50 intensifier pump in action.

The 'heart and soul' of the Jet Edge waterjet cutting system, the iP60-50 intensifier pump is rated for 60,000 lb/in2 and features an extended-life hydraulic system.

The iP60-50 intensifier pump provides easy access for all service and maintenance.

It features non-threaded high-pressure components in the high-pressure cylinder, an improved performance check valve, and low torque values.

The Jet Edge iP60-50 intensifier pump leads the industry with ease of operation and low operating cost.

It requires very few tools to maintain.

The cutting system is controlled by the AquaVision Di motion controller that guides users through the process from job set-up to production.

With the AquaVision Di, single parts, part arrays, mirroring, scaling, rotation, and plate alignment are right at users' fingertips.

The AquaVision Di is fully networkable, allowing part programs to be generated offline and easily transferred to the system's hard drive for production.

Feed rate and acceleration are automatically varied, based on known features of a specific job.

Dynamic tool offset, or 'cutter compensation', is employed real-time, and an optional real-time pump control allows remote starting and stopping of the pump, dual pressure set points for piercing hard-to-pierce materials, and unlimited data logging of every process parameter imaginable.

The AquaVision Di includes a full-featured hand-held pendant that allows feed rate override, return-to-path, program zero set points, and XYZ axis control.

Show participants are sure to be impressed by Jet Edge's new Digital Readout for Multi Head Positioning, which improves productivity by reducing setup time.

The Digital Readout for Multi Head Positioning digitally displays cutting head positions, eliminating manual measurement.

It is an excellent addition to your Jet Edge waterjet cutting system.

* About Jet Edge - Jet Edge is a global designer and manufacturer of ultra-high pressure waterjet systems for precision cutting, surface preparation, coating removal, and hydro demolition.

Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.

High power plasma-arc cutting offers quality

2007-01-04T23:43:00.000-08:00

High amperage high definition plasma-arc cutting and marking system offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality.

High power plasma-arc cutting offers quality High amperage high definition plasma-arc cutting and marking system offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality. With innovative design features that raise the bar on true precision plasma-arc cut edge squareness and offer unparalleled consumable life, Kaliburn's new Spirit275a system is the company's most advanced cutting system ever. Coupled with its recent unveiling of a new corporate name and brand identity, the introduction of this revolutionary new product marks another significant milestone for the company and solidifies its positioning as a leader in the plasma-arc cutting industry.

This high amperage high definition plasma-arc cutting and marking system from Kaliburn offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality.

Through technological advancements, the Spirit275a is designed to deliver virtually dross free cuts with minimal face beveling.

'In the spirit of Kaliburn and our commitment to superior quality, we describe the precision plasma process in traditional terms of minimal cut face bevel,' commented Steven F Hardwick, president of Kaliburn.

'At Kaliburn, we set higher standards for ourselves and manufacture products that deliver uncompromising cut quality for our customers and end users, and we are extremely excited about our new Spirit series,' he added.

Spirit275a is a 275A system that offers production cutting of steel up to 1.1/4in (31mm) thick, with a maximum capacity of 2in (50mm).

This expanded thickness capability plus its optimized cutting speeds, unparalleled consumable life and low operating costs make the Spirit275a the ideal choice for production shops demanding the highest in plasma-arc cutting performance.

Additionally, the system is convenient and easy to use with the Automatic Gas Console (AGC) that automatically sets process parameters, displays the required torch parts and part numbers, and monitors the parts' usable life.

The system is available with the patented Inova torch height control system, which sets all vertical height and arc voltage parameters, further simplifying operation and maximizing versatility and torch consumable life.

The Spirit275a is one of three fully automatic systems in the Spirit series of products.

Other Spirit systems provide identical cut quality and each offer a unique amperage range and corresponding thickness capacity.

In addition, Kaliburn offers three similar systems in a less automated configuration that deliver identical cut quality, but require manual process parameter setting.

These systems are great choices when budgets are limited, yet superior cut quality is necessary.

Established in 1985, Kaliburn (formerly Innerlogic) has flourished from a producer of torch height control products into an industry leading manufacturer of plasma-arc cutting systems.

Headquartered in Charleston, South Carolina, USA, the company is committed to delivering innovative, reliable products backed by unprecedented customer service and product warranties.

Through its significant growth and product advancements, the company continues to evolve and maintain its leadership position in the plasma-arc cutting industry.

Operate waterjet cutting machines at IMTS

2007-01-03T23:33:00.001-08:00

Waterjet cutting systems manufacturer offers the IMTS oppurtunity to literally work with the machinery, software, components and products, which are built to be expandable.

WARDJet, a manufacturer of waterjet systems is taking a unique approach to displaying their product at IMTS in 2006. Attendees will have the opportunity to literally work with the machinery, software, components and products. Designed to be functional, practical, easy to service and maintain, WARDJet's waterjets are built to be expandable and grow with users as their businesses flourish.

These multifunctional units come with an inspiring list of options that can be added at any stage, like water-only cutting, laser alignment, drilling and reaming, rotary axis pipe cutting, automatic height sensors and adjustment, wireless pendants, live video monitoring and much more.

Integrated clamping, jig and fixturing allow quick and easy loading, cutting and unloading of parts.

It is clear that WARDJet, when selling off their large job shop division in 2003, took all the knowledge gained and incorporated everything into these sturdy machines.

Plasma-arc system offers precision cutting

2007-01-03T23:33:00.000-08:00

Plasma-arc cutting system system produces high-speed, low-cost operation; high-quality precision cutting and marking; and high-current, thick-plate cutting - all with a single plasma torch.

ESAB's new m3 Plasma System combines multiple plasma cutting and marking features in a single easy-to-use system, taking plasma cutting productivity to new heights. The m3 system produces high-speed, low-cost standard plasma cutting; high-quality precision cutting and marking; and high-current, thick-plate cutting all with a single plasma torch. When configured for 600A operation, the system can quickly and accurately cut and mark material from 20 SWG to 6.25in (1mm to 160mm) without sacrificing cut quality.

The m3 Plasma System will be on display at IMTS Booth B6157.

The key to this new system is the new state-of-the-art PT-36 torch design.

Instead of setting a fixed cutting current and adjusting other parameters to achieve the desired cutting result, ESAB starts with the desired result and then determines the best parameter settings, including current, needed to achieve it.

This design allows ESAB to achieve superior cutting and marking results over a wide range of materials and thicknesses while using the fewest consumable parts in the industry.

The new PT-36 torch replaces up to three single-purpose torches (heavy plate cutting, precision cutting and marking) and produces a superior cut face with low dross, requiring little secondary clean up.

The end result is superior cutting functionality and productivity, with minimal set-up time, downtime and consumable cost.

The new torch can function in both dry and water injection modes.

The m3 system features the most advanced gas control system in the industry, fully automated by ESAB's Vision CNC.

Great flexibility in selection and mix of shield gases allows an operator to produce the best cut quality on any material.

The operator simply selects the material type and thickness, and the Vision CNC automatically selects and mixes the optimal start, cut and shield gas combination.

Process parameters for most plasma cutting and marking applications are preloaded in the Vision CNC, and custom parameter files can be easily created as needed.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

Plasma-arc and waterjet cutting combined

2007-01-02T23:32:00.001-08:00

A CNC multi-process waterjet cutting system uses ESAB's patented waterjet/plasma combination to produce cut parts using the speed of plasma-arc and the accuracy of waterjet.

ESAB Cutting Systems will demonstrate the Hydrocut LR multi-process waterjet cutting system at IMTS, Booth B6157. This CNC shape-cutting machine uses ESAB's patented waterjet/plasma combination to produce cut parts using the speed of plasma and the accuracy of waterjet. The waterjet process can also be combined with many other cutting or marking process tools, including oxyfuel cutting, plasma marking, ink-jet marking, routing, drilling or scribing.

The advantage of combining waterjet and plasma on the same machine is that both tools can be used on the same parts.

Contours requiring high precision can be cut with waterjet, while other contours can be cut with plasma.

This system allows users to produce the precision contours they need without sacrificing speed on every cut.

The Hydrocut LR is a precision gantry on floor mounted rails, featuring digital AC drives, brushless AC motors and precision planetary gearboxes.

The machine delivers smooth, accurate motion for the most precise cuts on a wide variety of materials.

Hydrocut LR features positioning accuracy of +/-0.010in over 3ft in each axis, and repeatability of +/-0.002in.

A maximum positioning speed of 600in/min keeps traverse time to a minimum.

Combined with ESAB's high-speed lifters and integrated process control, this speed delivers maximum throughput and low cost per part.

The Hydrocut LR is available with cutting widths of 8ft to 20ft.

It can be equipped with up to four waterjet cutting stations, along with a wide variety of other cutting and marking process tools.

When combined with ESAB's m3 Precision Plasma system, the Hydrocut LR provides the ultimate tool for maximized production and precision cutting.

Automatic height control for both waterjet and plasma processes allows underwater cutting with the waterjet and plasma tools.

This reduces noise, fumes, plasma glare and abrasive spray.

The automatic height control also allows unattended cutting.

Operators can perform other jobs while the Hydrocut LR is working and not worry about the waterjet nozzle or plasma torch crashing.

Large parts can be produced with minimal supervision because the height will remain constant.

The Hydrocut LR can be equipped with waterjet systems from 30 to 100 HP and with plasma systems from 100 to 600A.

ESAB's m3 Precision Plasma system provides high precision cutting on carbon steel, stainless steel, and aluminum from gauge material up to 6in thick.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

Software covers different cutting machine systems

2007-01-02T23:31:00.001-08:00

Programming and nesting software package is designed specifically for plasma, oxyfuel, laser, and waterjet cutting and supports straight and bevel cutting, as well as all current marking devices.

ESAB Cutting Systems will demonstrate its Columbus Programming and Nesting Software at IMTS, Booth B6157. Columbus is an advanced software package designed specifically for plasma, oxyfuel, laser, and waterjet cutting. The first cutting software package developed and maintained by a cutting machine manufacturer, Columbus supports straight and bevel cutting as well as all current marking devices.

At the core of the Columbus system is the Vision PLUS Desktop.

This base module contains numerous functions that conveniently enable the creation of machine programs from geometrical information.

A set of integrated modules can be combined as a seamless package to provide exactly the features and capabilities needed for a given application.

Included with the standard Vision PLUS Desktop is a comprehensive set of modules that provide basic programming capabilities and serve as the foundation for additional optional modules.

The Automatic Nesting module adds fully automated true shape nesting to the Vision PLUS Desktop system, providing Part-In-Part Nesting, Multiple Torch Nesting, Common Line and Bridge Cutting, and many other powerful features.

The user can control all aspects of the nesting process, such as the number of cutting heads to be used, priority of each part in the nest, cutting sequence or material grain limitations.

Parts can also be selected by weight or size to ensure the best optimization possible.

The Data Management Module (DMM) provides part management and tracking capabilities, converting the nesting system into a powerful tool for production control.

Delivery date, material required, and nesting priority of a part can all be specified.

This module allows a user to automatically track the part/order through the entire process and track what plate was used to cut the part.

The Plate Management Module adds plate inventory and remnant tracking capabilities to accurately track plate inventory and utilize every scrap of plate, maximizing profits through maximum plate utilization.

The 3D Transition Programming Software allows quick and easy development of three-dimensional transitions.

Graphical selection of the shape and graphical 3D displays make it easy to create the desired transition.

The software automatically unfolds the 3D shape into a 2D program for cutting.

When used in conjunction with ESAB's Vision PLUS CNC package, Columbus software allows machine operators to post DXF files and draw parts right at the Vision PC or Vision NT controller.

Vision PLUS CNC includes many features that simplify creation of a CNC program from geometrical information.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

Abrasive waterjet cutting machine introduced

2007-01-01T23:31:00.000-08:00

A large format abrasive waterjet cutting machine for fabrication shops uses direct drive pump technology to cuts parts faster and more accurately than with intensifier pump technology.

Omax is proud to announce the launch of The Fabricator JetMachining Center, the newest addition to its industry-leading line of abrasive waterjet machining products. The Fabricator offers large format abrasive waterjet cutting for stone and tile, and fabrication shops, at an affordable price - and like all Omax machines using their direct drive pump technology, it cuts parts faster and more accurate than conventional waterjet machines using Intensifier pump technology. Perfectly suited for those working with large workpieces, The Fabricator possesses a 4000mm x 2000mm width cutting envelope, with unlimited length expansion available in 2000mm increments.

A 272kg (600lb) abrasive hopper helps to ensure maximum machine utilisation.

The Fabricator uses a single or twin Maxjet 5 nozzle and ultra-high pressure direct drive pump to provide maximum speed and accuracy through high-pressure waterjet cutting.

The machine also achieves a high quality surface finish that reduces or eliminates the need for secondary operations.

Efficiency is further enhanced through the use of the Omax patented intuitive motion control system incorporating Windows XP software.

The Fabricator is capable of machining a broad range of materials including extremely hard, reflective and nonconductive materials and thicknesses.

Compared to traditional machining methods, The Fabricator offers much faster and easier set-ups, with minimal fixturing requirements.

It also cuts without creating heat-affected zones or mechanical stresses in the material being machined.

Like all Omax products, The Fabricator comes with the Omax Technology Guarantee, which provides updated software to all existing customers at no additional charge.

Investment brings waterjet cutting 'in-house'

2007-01-01T23:30:00.000-08:00

Installation of a waterjet cutting facility equipped with a 50HP intensifier has enabled a ceramic tiles manufacturer to provide even better service and not have to rely on sub-contractors.

As one of the leading importers and distributors of high quality ceramic tiles, Inter Ceramica of Harrogate has an established reputation for providing both standard and customised products for its extensive customer base. The company's decision to invest in its own in-house waterjet cutting facility, including a Powerjet Systems cutting table and KMT Waterjet Systems intensifier, was made in order to provide even better service and not have to rely on outside sub-contractors. The Powerjet Systems 3x2 metre Maxi waterjet cutting table equipped with a KMT 50HP Streamline SL-V pump has proven to be a highly successful investment.

By handling all the cutting in-house the risk of tiles being damaged during transportation has been severely reduced.

It has also given Inter Ceramica more freedom to create new designs and to produce more specials and one-offs.

These value added services are bringing valuable extra customers and income to the company which is already paying back the capital investment.

Powerjet Systems and KMT's joint experience in waterjet cutting of ceramics was important to Inter Ceramica.

They had the opportunity to view other similar installations and see the benefits first hand.

One of the most important of these was the simplicity of the process and the ability of operators able to run the machine after just a few hours training.

Inter Ceramica's installation features off- line programming, Baldor based drive systems and Powerjet's own software.

The KMT Streamline SL-V intensifier is a critical part of the installation.

Its compact design and minimal space requirement means that it can sit conveniently alongside the Maxi table within a dedicated area at Inter Ceramica.

With its plug and play technology the Streamline was easy to integrate with the table.

The pump's reputation for reliability, easy maintenance and lower operating costs were important considerations for Inter Ceramica, who relied upon the experience and know-how of both Powerjet Systems and KMT when considering the investment.

The pump features Klockner Moeller PLC-based control, ceramic plungers and the patented KMT Hard Seal End Cap topwork design.

The installation has been a major success and helped to further enhance Inter Ceramica's already impressive reputation for high quality products and first class service.

Dynamic nesting simplifies sheet metal profiling

2006-12-31T23:29:00.001-08:00

With the introduction of dynamic nesting each sheet thickness is only ordered in one size, simplifying the nesting process and making significant savings in labour and work in progress costs.

Finlay Hydrascreens was formed in the late 1950s with the aim of producing mobile screening equipment. Now the company is part of the Terex Group and specialises in screening, washing and recycling machines. Due to the harsh operating environment the design and manufacture of high quality, robust machines is of crucial importance to the company, which has a range of 22 main models.

The Trommel machines are designed to separate a wide range of materials including topsoil, compost, demolition waste and wood chips, while the Reclaimer machines, designed for the recycling industry, can also be used in the quarry industry for prescreening rock prior to crushing in the company's Jaw Crusher machines.

For washing applications, Finlay produces a range of machines for applications such as the washing of sand and gravel, crushed rock, quarry dust and recycled concrete.

The company carries out the design and build of these machines at its factory in Omagh, Northern Ireland and they are manufactured from a range of material including sheet metal ranging in thickness from 2mm to 25mm.

Brian Forbes, plasma programmer, said, 'All our production goes through our six Messer Griesheim plasma machines, which have bed sizes up to 12m long.' Finlay Hydrascreens decided to review its programming methods for the plasma machines, and chose SigmaNest from SigmaTEK Europe because of the power of its nesting package.

Forbes continued, 'SigmaNEST produced the best nest with the optimum material utilisation and was easier and quicker to use.' The design of the machines is carried out in Pro/ENGINEER, then DXF files of the component geometry are loaded into SigmaNEST ready for processing.

Initially, the company had created a series of fixed nests to meet demand for its products.

However, due to fluctuating order levels and customer's special requirements, this method of production resulted in shortages of some components and over supply of others.

Brian Forbes said, 'To solve the problem we moved to dynamic nesting, installing SigmaTek's SimTrans software to communicate with our MRP system.' Each week the plasma cut part requirements at Finlay Hydrascreens can be for 6000 different plasma parts, each of which can be required in various quantities, cutting up to 22000 parts per week.

'With SimTrans, we automatically get a list of parts for the week from our MRP system.

We can then, for example, nest all the 5mm thick parts for customer A, and then create another nest for customer B and so on.

The SigmaTEK software keeps track of the nested parts, only showing us the ones yet to be processed.

By the end of the week all the components are finished and we are ready for the next week's production.' Since its introduction, production has risen from 220 to 430 tonnes per week which requires approximately 600 different nests and is set to rise further in the coming months.

Forbes added, 'It would have been impossible to raise production to these levels without SimTrans.' SigmaNEST and SimTrans have also enabled the company to rationalise its sheet metal purchasing.

Fixed nests required sheet material in multiple sizes for each thickness.

The result was high stock levels and storage and handling problems in the factory.

With the introduction of dynamic nesting each sheet thickness is only ordered in one size, simplifying the nesting process and making significant savings in labour and work in progress costs.

The software helps in the identification of parts.

Each nest automatically generates part labels and sketches for each component.

The machine operator can then easily sort the parts and correctly label them ready for subsequent operations.

Forbes said, 'This is a simple and effective way of keeping track of our components.

Our next aim is to have colour coded labels so that we can easily identify the customer too.' Flexibility is provided by the ability to manually intervene in the automatic nesting process.

Parts can be added to fill up partially used sheets for maximum material utilisaton.

Finlay Hydrascreens has recently benefited from an upgrade to version 7, which gives faster nesting and easier retrieval of parts in SimTrans.

Forbes concluded, 'Nesting in SigmaNEST version 7 is at least twice as fast.

The processing of five sheets can be completed in 20 to 30 seconds.

The quality and speed of nesting which we can achieve with the software is very important to us.' * About the SigmaTEK Corporation - formed in 1992, with offices in Cincinnati, Ohio, Seattle, Washington - USA; international offices in Europe, Japan and Australia, and a worldwide distribution network, over 4000 SigmaNEST systems are now in use round the globe.

SigmaNEST software maintains its technological leadership in sheet metal nesting and cutting by a relentless commitment to research and development, providing customers with tools to maximise material utilisation and increase machine throughput while minimising programming time and effort.

Authorised training centres around the world provide after sales technical support and education to optimise productivity for users.

Water jet cutting is very versatile and burr-free

2006-12-31T23:29:00.000-08:00

Highly versatile waterjet cutting offers major advantages in terms of accuracy of cut, limited material distortion and almost burr free edges, as will be demonstrated at EuroBLECH, Germany.

KMT Waterjet Systems is the leading worldwide supplier of waterjet cutting systems and at euroblech 2006 the company will be underlining the quality and high reputation of its Streamline, Active Autoline, Aqualine, Abraline and Feedline branded products. Another major attraction will be the new Streamline SL-V 200 high pressure intensifier which has a power rating of 200HP and also offers economic running costs and reliability, providing maximum waterjet cutting performance. Highly versatile waterjet cutting is acknowledged as offering customers from many different industrial sectors major advantages in terms of accuracy of cut, limited material distortion and almost burr free edges.

Whether cutting metal, plastics, ceramics, exotic and other materials, pure and abrasive waterjet cutting processes are fast, economic and accurate.

In order to achieve an operating pressure of around 4.000 bar, which is commonly required for many applications, advanced pump technology is required.

KMT Waterjet Systems provides this with the Streamline SL-V 200, which gives a powerful water flow and can operate 'around the clock' without interruption.

The major benefit is that the 200HP power rating is achieved by two intensifiers in a standard configuration.

This is a unique combination and the result is not only reduced space in the workshop, but also a minimisation of wear parts resulting in reduced operating costs and maintenance.

The flow rate of one single intensifier is 7.6 litre/min, so that the pump can supply up to 15.2 litre/min at full load.

It is also possible to switch off on intensifier when servicing is required.

A further advantage of the Streamline SL-V 200 is its patented Hard Seal Endcap Design (HSEC).

This design provides a metal-metal seal, eliminates traditional seals thereby reducing consumable costs and downtime.

The bolted end cap is also much easier to assemble at a maximum torque of just 48Nm.

For further economy and flexibility, the Soft Start feature reduces the electric current peaks to a minimum while the pump is accelerating to full speed - this provides up to 20% energy savings in power consumption when the pump is switched on.

Now water jet cutting machines get linear drives

2006-12-30T04:27:00.001-08:00

When applied to a water jet cutting machine, the whole X-axis is fitted with a linear motor, so the X-axis movement of each cutting head can then be accurately controlled to 0.05mm.

Water Jet Sweden is believed to be the first manufacturer of water jet cutting machines to incorporate linear drives in this technology for customers who have discerned the technical advantages of this option. Increasingly already being applied to advanced machine tool designs, linear drive systems are now being taken up by designers of other types of machinery and equipment used in a variety of manufacturing processes throughout the world. In the case of Water Jet Sweden, the close collaboration enjoyed between themselves and CNC suppliers GE Fanuc over recent years has seen the introduction of a linear drive option across the range of profilers produced at the busy Ronneby factory in southern Sweden.

With the entire linear drive system being sourced from the same supplier as the other drives systems on the machine, plus the CNC control, the whole package is totally integrated and thereby offers assured reliability.

* Great accuracy - when applied to a Water Jet Sweden machine, the whole X-axis is fitted with a single flat magnetic plate.

The X-axis movement of each cutting head can then be accurately controlled by the CNC with a positioning accuracy as fine as 0.05mm by means of coils fitted to each head.

Lennart Svensson, managing director of Water Jet Sweden, said: 'As well as the well-known advantages of such a drive system, it is especially useful for multi-head profiling.' He cited the many cases where nested items need to be cut using the 'common line' method whereby the intermediate heads of a multi-head arrangement are cutting a line that forms both an 'inside edge' of one component and the 'outside edge' of its companion, thereby simultaneously eliminating the wasteful 'picture frame skeleton' left in the sheet.

Significantly, because each of the heads can be easily re-positioned independently, it is far quicker to replace any one or more nozzles as wear takes place.

This nozzle wear can be compensated for automatically which is an attractive time-saving proposition in a busy shop.

* Other advantages - such drive systems cannot be affected by that small element of component wear that might occur over long periods of time with other drive systems.

Additionally, there are no backlash or pitch error problems to worry about.

The improved long-term positioning accuracies achievable are an added incentive to adopt the linear approach.

The application of a linear drive system to a waterjet profiler is a good one because, unlike other metal cutting machines, there is no swarf or coolant present that might pose a risk to lifelong performance.

In any case, the X-axis drive is mounted on top of the cross gantry where it is well above the work interface.

It is, therefore, in the field of multi-head, high-volume work that the linear drive option can really prove its worth, especially when the added advantages of increased positioning speed and acceleration while profiling are taken into account.

Water jet cutting machines are getting larger

2006-12-30T04:26:00.000-08:00

Much larger water jet cutting machines are in demand, such as a profiling machine of 4m x 18m long, which is to be supplied to a German rolling mill, and another operating at a sheet steel mill.

Although offering an unprecedented range of more than 90 standard waterjet profiling machines, all based on the concept of portal design and employing high tech components and systems, Water Jet Sweden now finds itself firmly-established as a market leader meeting a surge in the new demand for much larger capacity installations where machines need the table to be at least 6m long. * Germany leads the way - a good example is the 4m x 18m long WJS profiler, believed to be the biggest in Germany and probably the world, currently under construction and due for delivery before the end of 2006 to the steel rolling company Dillinger Hutte. Not only can Water Jet Sweden's machines such as these handle very large workpieces, thanks to easy transverse access through the portal, but can perform also water jet parallel profiling operations by using several cutting heads mounted along the cross beam.

Moreover, large format machines enable the principle of a divided cutting table to be put into practice, thereby creating an even more economical operational regime.

* WJS installation with workpiece area of 4.2m x 9.2m - Universal Iron and Steel, based in Neuss, is one of Germany's largest retailers of unfinished sheet metal in the steel industry and has a current inventory of 80,000 tonnes, along with a monthly turnover of around 20,000 tonnes.

The branch site at Viersen is concerned exclusively with the processing of refined steels and it stocks up to 1,300 tonnes of various grades of steel at any one time.

The traditional thermal cutting procedures, such as underwater plasma cutting, could handle sheet thicknesses in the 6 to 150mm range.

The Water Jet Sweden NC4492-D now installed is the only one in Germany with a maximum workpiece area of 4.2m x 9.2m and a maximum cutting area of 3.6m x 8.5m.

The machine has now been in operation for several months and is set up for cutting sheet thicknesses from the required maximum of 150mm down to a new low of only 0.5mm which brings great flexibility to the user.

Said Manfred Salg, Universal's branch manager of Refined Steel services, 'Universal is currently the only company in Germany able to cut its whole range of refined and special steels to this desired dimension and precision in-house.' Salg said, 'The main reason for this investment into waterjet cutting was to enlarge our range to include heavy-duty materials such as nickel and cobalt alloys, as well as titanium and titanium alloys.' He added: 'However, this was dependent upon finding an effective and economic process that would fulfil the requirements of cutting quality and tolerance without heat reaction or delay.

We needed also to 'machine' the largest possible format from our classic refined steel product range and this extends to 3.5m wide by 8m long.' Other machine choices were out of the question, as they could not meet the desired specification and, additionally, the quality of the test pieces cut proved decisive.

* 'Side-by-side' cutting - another advantage is that the portal construction of WJS profiling machines makes for easy side-by-side cutting.

Thus, for example, the machine can be set up easily with four cutting heads.

This allows a marked increase in production - without loss of quality.

The high cutting quality, even in very thick materials, is due, amongst other things, to the patented construction of the cutting heads.

Moreover, they use up to 20% less abrasive material than comparable machines.

The machine comes equipped with collision and height sensors as standard, although this is not so important for Universal, as hardly any curvature is involved - something that would be different with plasma cutting because of potential heat distortion.

Guidance of the unit comes from an especially-developed GE Fanuc 310i CNC control system.

Cutting pressure of up to 4,200 bar is provided by two Bohler Dynatronic 424 high pressure pumps.

One interesting point for the business is that the operating area of the Z-axis is up to 250mm.

This allows for the cutting of pieces thicker than 150mm for aluminium and titanium.

* The largest in Switzerland installed by Water Jet Sweden - the Swiss company, Stahl-Contor, Zurich, since 1929 has successfully-established itself as a specialist in the working of and trade in stainless steel.

As such, they have gained a renowned reputation for competence among an ever-increasing number of satisfied customers.

As the leading supplier in Switzerland of various types of highest strength steel plate as used for armoured tanks, cranes, bridges, etc, an investment in waterjet cutting required the closest scrutiny of the system in order to ensure both maintaining and improving the high standards of quality and efficiency expected of them.

Having decided these necessary standards could be met by Water Jet Sweden, a five-axis WJS NC 3592 machine was ordered and installed at the beginning of 2006, which marked the start of a fruitful partnership between customer and supplier.

The installation, one of the most advanced and largest in the whole of Switzerland, having a workpiece of maximum size area of 3m x 8.5m, has more than justified its selection, whether for single part or mass production, semi-fabrication or finished components, and whether from just a sketch plan, drawing, or CAD system.

2D or 3D cutting heads facilitate economic parallel cutting.

Stainless steel is cut to a maximum thickness of 150mm.

Jet pressure of more than 4,200 bar guarantees clean cutting and high precision.

Accuracy tolerance of less than 0.1mm fulfils all the requirements of not only the sheet metal industry in general, but also those engaged in plant and machinery building and the automotive industry.

* A WJS profiler with four cutting heads plus linear drive for workpieces 4m x 6m - earning its keep at Schroeder Schneidtechnikin Guetersloh, is the latest machine from WJS, the new NC4060 Quad.

The first of its kind in Europe, it combines high-precision linear drives with four side-by-side cutting heads.

This company began a contract-cutting service in the waterjet sector six years ago and also offered rapid prototyping of pieces.

Materials dealt with range from metals such as refined steel and aluminium through plastics and ceramics to 'sandwich' construction parts.

Prior to installing the WJS machine, all work had been carried out on a two-three shift system on a 2m x 4m machine with two heads.

Frequent re-adjustments of the machine were needed and managing director, Raphael Schroeder, also had to decline opportunities for producing larger parts.

* Close tolerance accuracy of +/-0.05mm - the WJS machine was able to resolve these problems.

After various test cuts on different companies' machines, the decision came down to the precision that could be achieved cutting special small springs to a tolerance of +/-0.05mm.

The competition was won by the WJS NC4060Q.

The customer asserts that these test pieces had never been cut so precisely before.

Schroeder explained, 'The purchase of this machine was without question a major investment for us.

It offers though the advantage of improved economy, noticeably greater accuracy and the ability to handle much larger workpieces.

Another important factor in our decision was that we could specify the high pressure pump of our choice.' * Virtues of linear drive - cutting precision was due not only to the quality of the Swedish machine, but also to a significant innovation - the linear drive.

Above all, an expensive linear drive makes sense only when used in conjunction with multiple cutting heads whereby they will all cut identical contours over long periods of time.

This is the reason that the WJS NC 4060Q is equipped with four abrasive heads.

Compared with a rotary motor with ball-driven spindles, linear drive offers greater precision, minimal wear and tear and no need for attendance.

Because of the construction of the linear drive, movements are carried out in the most precise way and all other sources of faults, such as gearing, linkage, transmission drive and ball-driven spindles, are avoided.

This results in a noticeably greater accuracy of contour compared with the spindle drive, particularly over a long period of work.

'And that was precisely where we always had problems in the past,' said Schroeder.

* Automatic adjustment - one of the most important points before starting a job is the setting up of the cutting head(s) clearance.

There are still many basic models on the market with manual adjustment.

The more expensive machines, however, use an automatic adjustment with this axis becoming fully CNC.

Linear drive, in conjunction with a corresponding guidance system, offers far greater flexibility and here, the Fanuc CNC control system is used for all drives.

During cutting, the correct clearance of the cutting heads is automatically taken care of by a mechanical height sensor.

A further advantage of this guidance system is the convenience of remote monitoring of the machine.

Even the smallest machine from Water jet Sweden comes with a Fanuc guidance system as standard but NUM-Schneider or Siemens systems are available if requested.

The patented cutting heads are an economically important aspect of all WJS machines: they consist of only three parts; the mixing chamber is located in the pipe and, compared with other machines, uses 15-20% less abrasive materials.

The benefits of this are very noticeable when purchasing and disposing of the abrasive material.

'The machine has two further special features,' said Schroeder proudly, 'A special device for removing the silt, which sucks it out from around 40 places, and an additional removal tank for regulating the water level.

Thus the machine has been custom-built to our exact requirements.' * WJS profiler 3 x 6m long 18 tonnes capacity with divided table - with a 6m long table generally recognized as the starting point for 'large' profilers, some of the above-mentioned advances are featured also in the Butzbach factory of CAN Industrieservice, where WJS has installed a typical 3m x 6m profiler.

Established in 1997, and traditionally using oxy-fuel and plasma devices, CAN produces rotating and non-rotating components for the pharmaceutical and oil industries, as well as for sewage treatment.

However, in contrast to previously used thermal techniques, waterjet is a cold cutting process and is the only method of cutting such a wide range of materials with great precision and without burrs.

Materials can range from refined steel and aluminium to plastics, ceramics and even 'sandwich' style combinations of materials.

There being no residues from heat-affected or melted zones, no microscopic cracks are formed on the cut edge.

CAN-chief, Mityesoglu, said, 'Previously, quite apart from the fact we always had to undergo secondary processing, we had to send large items to a third party for cutting.

Now we can cut everything on our own water jet profiler.' * Divided table - the divided cutting table installed at CAN offers several advantages compared with the more usual interchangeable types.

Not only is the overall footprint smaller than a machine with interchangeable cutting tables, but the waterjet solution is also more economical.

While cutting is still being carried out on one side, the other side can be cleared or set up.

Another advantage of the machine is its high total load capacity of 18 tonnes.

That is, nine tonnes on each half of the cutting table.

With its new WJS NC-3060D machine, CAN can now with ease cut heavyweight refined steel and C-steel components such as wiper blades installed on the rotors of sludge driers, rings for flanges and base plates for traverses and seals.

More unusual orders can now be taken for such items as parts for coolant return systems for nuclear power stations.

The cutting of plated and laminated sheets has been noticeably simplified in comparison with plasma cutting where there was always the danger of the refined steel coming away from the base substance.

The new machine not only needed to be compact and cut precisely, but also allow for the handling of large pieces of typical rough sheet as large as 3m wide by 6m long.

CAN made their final choice only after considering other machines from both Germany and Switzerland.

Said Mityesoglu, 'The final decision in favour of WJS came down to the higher quality of the cuts achieved during tests.' * Service and support - most WJS customers invest in a complete system, including controls and pumps etc The value of having one single point of contact should not be underestimated.

Potential users who are not sure whether waterjet cutting is a logical investment for them, either as an alternative process or as a supplement, can try before they buy.

The Water Jet service centre in Weinstrasse, Neustadt, Germany, for example, can be used for contract cutting initially, as can the same facility at the parent company in Sweden.

* Consumer durables - WJS is justifiably proud of its reputation for incorporating only high quality components that retain their precision and efficiency over long periods of hard usage.

Some users, however, have been found to put these high levels of performance, accuracy and reliability at risk by the purchase of key consumables from sources other than the original manufacturers.

The use of cheaper (and therefore usually inferior) garnets and nozzle inserts for example, not only have been the cause of marked performance deterioration but also can lead to the original supplier's warranty on key components, such as pumps, being invalidated.

Waterjet cutting process guidebook produced

2006-12-29T02:45:00.003-08:00

A guide to the technology and benefits of the waterjet cutting process provides information on alternative pure water and abrasive waterjet cutting technologies and applications.

A guide to the technology and benefits of the waterjet cutting process has been introduced by KMT Waterjet Systems. The world leader in intensifier technology has been in the market for over 50 years and provides waterjet solutions for many different market sectors from engineering sub-contracting and general fabrication through to specialised applications in areas as diverse as food processing, ceramic tile cutting, textiles and rubber cutting. The guide provides information on alternative pure water and abrasive waterjet cutting technologies, highlighting their possible application areas.

Information is also provided on how the waterjet process compares with other cutting processes and its relative advantages in terms of cost savings, flexibility and versatility.

Copies of 'Waterjet Cutting - A Technology On The Rise' are available from KMT Waterjet Systems.

Slab laser has 5kW for high cutting speeds

2006-12-29T02:45:00.001-08:00

To offer increased cutting performance, a 5kW diffusion cooled CO2 slab laser with a high energy density to provide improved process stability and high quality at high cutting speeds.

In response to customer's needs for increased cutting performances, Rofin introduces the DC 050. With an average output power of 5,000 Watts this diffusion cooled CO2 Slab laser provides an ideal laser source for industrial plate and sheet cutting applications. 'We are glad to enlarge our CO2 product range with this new model,' said Thorsten Frauenpreiss, managing director of Rofin-Sinar Laser.

'The newest model of the mature DC series provides new possibilities for all cutting applications - especially for thick plate applications where the high-performance laser proves its quality.' Due to the excellent beam quality of the laser and its increased output power, high-pressure cutting with long focal lengths is now available in the 5kW power range, too.

Additionally, the high energy density provides improved process stability at high cutting speeds, a precondition for reliable cutting data and quality.

Thanks to the patented design, the low-maintenance Rofin CO2 slab lasers are easy to service.

Having no gas circulation, the laser does not need any turbines.

The gas bottle that is required for the gas exchange every 72h, is positioned conveniently within the laser head, so that an external gas supply is not necessary.

The laser beam that is produced in the resonator is uncoupled by a diamond window without any losses of power or beam quality.

The internal water-cooled mirrors, are robust and non-wearing reflective optics.

With its excellent beam quality of K0.9 this laser is at all power levels a perfect tool for manifold cutting and welding tasks.

Live-Demonstration of Ultra Large Scale Remote Welding The DC 050 shows his outstanding qualities as a welding laser together with the remote welding system (RWS).

In a live welding demonstration of vehicle rear seats, 49 welded joints are created within 12s.

The RWS is a high speed welding system, which is able to make multiple spot welds in an arbitrary pattern over a very large working area in a short time.

The variety of possible welds is nearly limitless, spots, circles, lines, waves or any other form.

Thanks to easy programming and beam forming through the mirror and scanner all applications can be set up quickly.

With a RWS a very wide working area is possible, because the laser beam is expanded by a telescope and focussed by an optic on the work piece.

Using a focal length of up to 2.0 meters gives a working area of 2900 x 1800 x 1000mm.

With a positioning speed of 400m/min between the welding points, known as 'rapid move', the non- productive time is reduced to a minimum.

This provides the shortest possible cycle times.

With about 20 million welding cycles for more than 300 km of weld length, without the exchange of typical wear parts, the system also sets a benchmark for availability and process optimization.

The laser is positioned above the working area so that, compared to a conventional manufacturing method like, e g, resistance spot welding, a compact system with the smallest possible footprint results.

* Patented CO2 laser technique for remote welding - the Remote Welding System will be presented at the euroblech fair in combination with a diffusion- cooled Rofin DC 050 with a average output power of 5kW.

This CO2 laser belongs to the patented Rofin DC series.

The excellent beam quality of K0.9 makes the use of remote welding cost-effective.

As all DC lasers have a perfect basic specification for high speed welding with large focal lengths, they are the ideal tool for this application.

When quick welding for complex formed work pieces is required, the Scanner Welding System (SWS) with a robot is the perfect solution.

At the EuroBLECH, Rofin will present this mirror deflection system in combination with a 6-axis articulated robot.

The mirrors offer extremely quick positioning (<50ms) of the laser beam within the considerably extended working area of about 200 x 240 x 80mm.

In comparison with the already industrially used RWS with its CO2 laser, in the SWS all three scanner axes are coupled with those of the robot so that the combined system has nine accessible axes.

Like in the Remote Welding System, weld geometry can be programmed freely, which means it can be adjusted specifically to the requirements of the component.

Furthermore, the sophisticated software has features that calculate the track inaccuracies of the robot so that the weld path is accurate to <0.1mm.

The resulting reduction of non-productive time allows an increase in laser on time from typically 30% to over 80%.

* Perfect features for scanner welding - the Rofin Disc Laser To be able to follow the movements of the robot, a flexible beam guide through fiber optics is needed.

At the EuroBLECH the SWS will be presented in combination with a diode- pumped disc laser.

The emitted laser light of this laser can be coupled with virtually no power loss into fibre optics of only 200 micron core diameter.

Compared to rod lasers this new solid state laser generation is distinguished by its nearly doubled efficiency and its improved beam quality of 8mm x mrad.

Because of this beam quality the working distance to the work piece can be increased to up to 400mm with the SWS.

Thanks to this extended distance, the danger of contamination of the optics can be significantly reduced, and the associated greater energy density leads to higher process stability.

At the EuroBLECH Rofin will also present the new DL-R series as cost-effective and compact tools especially for laser hardening and surface treatment.

Based on the mature DL series, these lasers have a wavelength of 940 to 980nm and rectangular beam geometry made for the hardening process.

Thanks to the homogenized beam profile and its resulting uniform energy distribution, large hardening depths are possible without initial melting.

The geometry of the rectangular focus spot is adaptable to match the specific needs of the customer's application.

The DL-R series was designed with Stack Management as a basic feature to ensure laser up-time.

Currently, four laser variations from 900 to 3,600W are available.

An online performance test and the observation of all important parameters provide highest availability - the pointing laser with green wavelength offers a better visibility.

The compact and low maintenance diode lasers have an overall efficiency of 30% and meet typical diode lifetimes far in access of 10,000 hours.

* Laser marking - the ideal tool for small order quantities - the ideal tool for small order quantities, different materials and forms: portable, air-cooled and almost maintenance- free.

The EasyMark can be programmed by effective LaserCAD-Software from any computer and operates from a common mains power supply.

With a wavelength 1064 nm the machine can mark metal and plastics precisely.

Optional program-controlled axes (a linear Z-axis and an axis of rotation with ring admission) can be integrated easily.

After a short period of instruction, the integrated focusing and positioning aids make for easy handling of the machine.

The EasyMark was especially developed for applications with manual operation and small order quantities.

World wide sales promotion program

2006-12-28T02:44:00.000-08:00

International Waterjet Machines (IWM) has announced its world wide sales promotion program.

International Waterjet Machines (IWM) has announced its world wide sales promotion program for the rest of year 2006. The latest sales effort includes recruiting of sales representatives, distributors, and special pricing on limited models. The company is inviting individuals and businesses that have prior experience in waterjet machines to join the company's sales force.

'We need people in every corner of the world to do marketing and provide after sell service' said marketing director John Martin.

Meanwhile, as part of the promotion, the company has some of the models and related spare parts on sale as a way to thank the support of the customers.

Interested customers are urged to contact the company directly to find out more details.

Abrasive waterjet cutting, CNC milling, stamping

2006-12-28T02:43:00.000-08:00

One of the America's largest steering wheel trim die manufacturers routinely cuts 4-6 inch thick heat-treated steel with abrasive waterjet.

One of the America's largest steering wheel trim die manufacturers routinely cuts 4-6 inch thick heat-treated steel with abrasive waterjet. If you've driven a car, truck or SUV lately, chances are the trim die used to make your steering wheel was manufactured by Trim Tool and Machine of Cleveland, Ohio. In business since 1999, Trim Tool and Machine is a traditional mom and pop shop that offers abrasive waterjet cutting, CNC milling, stamping and diecast tooling, and machine building.

The eight-person company serves a wide range of industries, from automotive to arts and architecture, and prides itself on its ability to turn work around within two to three days of an order, or even the same day if necessary.

'We turn work around for people,' said Owner Dane Willis.

'We get it in there and get it done.

If the customer needs it today, we get it done.

I will stay late and operate the equipment myself.

We do the job when we say we are going to do it.' Trim Tool and Machine specializes in gages, fixtures, trim dies, special machines, custom metal art and repairs, but is best known as one of the largest producers of steering wheel trim dies in the United States.

In fact, the company has produced trim dies used by nearly every auto manufacturer in the country.

A trim die is a specialized stamping tool made of thick hardened steel that is used to trim away excess metal from diecast castings, creating precise and consistent parts.

While many companies use wire EDM to cut their trim dies, Willis said he uses a Jet Edge abrasive waterjet system because it is much faster and more cost-effective.

'That gives me a competitive edge,' Willis noted.

'With waterjet it costs $3 to $5 to cut one inch versus $10 to cut with wire.

It's two-thirds more to wire cut something.

You can utilize waterjet for about 85 percent of the die.' While waterjet is best known for cutting thinner materials, Trim Tool and Machine routinely uses their system to cut thick hardened metals, including 9-inch thick 4140 heat-treated steel.

'We typically cut 4 to 6 inches all day long,' Willis said.

'Anyone that comes in says 'wow you cut thick.' We cut more thick stuff than anybody.

We design around it, and utilize spacers if necessary to reduce the taper.' Five years ago, to set himself apart from the competition, Willis invested in a 4-foot by 8-foot precision high-rail gantry waterjet system manufactured by Jet Edge of St.

Michael, Minn.

The machine is powered by a 50-horsepower Jet Edge intensifier pump capable of producing up to 60,000 psi of ultra-high pressure water.

Willis equipped his Jet Edge system with an extra large 5-foot by 13-foot tank to allow for future expansion with a spreader bar.

'I got the biggest one and best one I could,' he said.

Willis researched numerous waterjet systems for several years before deciding on Jet Edge.

The system's bridge-style overhead gantry appealed to him, as did Jet Edge's commitment to customer service.

'I was a one man show, and to be perfectly honest, Jet Edge was one of the only companies that talked to me,' he recalled.

'It looked like it was constructed better, and upon researching it, everyone raved about the pump.' Willis said Jet Edge has exceeded his expectations, and that when a friend asked him what type of machine he should buy, he told him he could only recommend three manufacturers, but that he would go with Jet Edge over the other two, mainly because of the company's excellent support.

'Jet Edge has been very good,' he said.

'The support has been good, the sales staff has been great and the service staff has been great.' Willis said his Jet Edge system has helped him increase productivity and reduce costs, saving customers' thousands of dollars and enabling him to expand his business.

'We have been able to maintain the cost of tooling despite the steel increase because we are using waterjet,' he noted.

Willis recalled one project where a customer needed to have 28 .281 inch holes cut in half-inch thick hardened A-2 material.

He was able to do the project for only $90 with his Jet Edge system.

'For someone to burn it or carbide it, it would have been hundreds of dollars,' he said.

'Waterjet can tackle hardened steel.' Trim Tool and Machine also has saved its stamping industry customers thousands of dollars by using its Jet Edge system to cut precise stamping strips that customers can use to make sample hits prior to making final adjustments to the cuts in the die.

'It saves them thousands of dollars in tryout time,' Willis said.

'The waterjet mimics the stamping process perfectly.

Laser and plasma leave a case-hardened edge.

When I talk a customer into waterjetting, they never go back to laser or plasma.' Willis noted that his Jet Edge system has been a huge boon to his business, and that his sales doubled the first year after he bought his waterjet.

'At that point I was able to start hiring people,' he said.

'I believe I would not have survived the post-911 industrial crash if I hadn't had the waterjet.

CNC laser cutter provides benefits at low cost

2006-12-27T02:42:00.001-08:00

The ability to quickly and easily produce profiled parts such as brackets and sling components is vital to Bramptons.

In his business almost every job is a one-off, says Neil Dowse of lift manufacturer Bramptons so the ability to quickly and easily produce profiled parts such as brackets and sling components is vital. Until recently these parts were cut using plasma, but when the time came for Bramptons to replace its ageing machine, laser cutting on a keenly-priced LVD Orion laser proved to be a much better option. 'Quality was becoming a real problem on the old plasma machine,' said Dowse.

'Not only were the hole quality and the dimensional accuracy poor, but the nature of the plasma process meant that we were spending a day cleaning parts after we had cut them.

'We had been looking at another plasma machine which would have cost around GBP 100,000, but then we found out about the LVD Orion and realised that we could have all the advantages of laser cutting for just GBP 65,000 more - so we bought one.' The LVD laser arrived in March this year, and he says that the quality improvement has been incredible.

'It's unbelievable.

There is no need to clean up the parts and they are absolutely accurate.

They come straight of the laser and are ready for bending.

We draw the parts up in Solid Works and we know that if the drawing is right then the parts will fit.

We don't have to rely on making holes three times bigger than they need to be to make sure they line up - we know that they will.

Our parts have to be of a high quality so that they fit together and look good; both of these are much easier to achieve with the laser.' Bramptons makes almost everything in a lift that isn't mechanical or electrical - from lift cars and doors to the steelwork that holds the lift in the shaft.

It supplies over a hundred lift cars a year, and maybe a thousand lift doors to most of the UK's independent lift companies, not just for new installations but also for refurbishment and replacement projects.

While the laser is normally used on 6mm mild and stainless steel, occasionally going up to 12mm, most of Bramptons' thinner material is normally processed on its CNC punch presses.

But even here the laser has been able to make an impact.

Every lift needs faceplates for the buttons and an indicator panel to show which floor you are on.

At one time the cut-outs in these were put in on the punch press.

In more recent years though there has been a trend for these items to become more bespoke 'architectural' items which made them almost impossible to punch.

The solution had been to engrave the holes out but they can now be cut on the laser much more quickly and easily.

Overall, says Neil, the laser is not only quicker and the quality better, but the ability to nest components means he can plan work more effectively too.

'When you are punching you have to wait until you've got the right number of jobs with the right mix of holes to load the turret up for maximum efficiency.

With the laser you can put whichever jobs you want on a sheet regardless of hole diameters or profiles, so you get less waste too.' He said that anyone looking at replacing a plasma machine shouldn't just look at the initial cost of the machine.

'You should look at all the aspects of the process and assess what the laser can do for you overall rather than just looking at initial cost of the machine.

Intensifier improves waterjet cutting quality

2006-12-27T02:42:00.000-08:00

Intensifier and an abrasive management system retrofitted to a waterjet cutting table has provided highly reliable operation, improved cutting speed and a consistent quality of cut.

A Streamline SL-V 50 HP intensifier and an AMS I Abrasive Management System manufactured by KMT Waterjet Systems have been retrofitted to a waterjet cutting table at AquaCut. The Knutsford, UK-based company has been established as an independent specialist sub-contractor for over 10 years and specialises in waterjet cutting for the production of logos, lettering and images in a variety of materials for signage, flooring and the development of exterior landscape features. AquaCut uses the power and versatility of waterjet to cut the materials, curves and more intricate shapes and designs that customers specify.

Lettering and signage is frequently cut from stainless steel brass and aluminium.

Flooring materials include marble, granite, tiles, pvc, linoleum, stone, slate, flotex and rubber.

For exterior landscape projects, hard materials such as paver bricks can be cut in thicknesses up to 65mm.

Only waterjet can cope efficiently with such a wide range of material or the intricacies of some of the shapes required.

AquaCut's skill is to take a customer's design and turn it into a computer generated detailed drawing.

A required design to be cut is then transferred to the computer of the cutting table.

Cuttings paths are worked out and abrasive waterjet cutting operations at pressures up to 58,000 lb/in2 are carried out.

The retrofit of the Streamline SL-V 50HP pump has provided AquaCut with a number of benefits including highly reliable operation, improved cutting speed and a consistent quality of cut.

Energy savings at start up are also made as a result of reduced power consumption.

The intensifier's Hard Seal End Cap design (HSEC) for the topworks provides a metal to metal seal, reducing consumable costs and minimising downtime for maintenance.

The quick release ceramic plunger also has reduced maintenance requirements and is easier to release when necessary.

Essential to the waterjet cutting process at AquaCut is the AMS I Abrasive Management System.

Including the Autoline abrasive cutting head, the Feedline III abrasive feeder and the Abraline abrasive transfer system, it is designed to automate and optimise the waterjet cutting process by ensuring exactly the correct delivery of filtered abrasive to the cutting need in accordance with the continuously monitored cutting process.

For AquaCut, the retrofit of the KMT Waterjet Systems' intensifier and Abrasive Management System have given an extra dimension to the capabilities of their cutting table.

'Waterjet cutting is fundamental to our business and KMT offers a proven product with good customer support,' said AquaCut managing director Nicholas Stephens.

Robots designed to sort laser-cut parts

2006-12-26T03:25:00.001-08:00

An intelligent 6-axis robot transfers the sheet steel from the laser profiler to its rotary table, sorts the finished parts into predefined load carriers and disposes of scrap.

Remmert, the German storage and logistics expert, will be unveiling an innovation exclusively at euroblech 2006: 'Laser-Sort 06', an intelligent robot system for sorting finished parts from laser machines. Visitors to the fair are welcome to inspect and try out the system for themselves at Stand B 58 in Hall 15. The 6-axis articulated robot transfers the sheet steel from the retrieval station to the laser machine's rotary table, sorts the finished parts into predefined load carriers and disposes of the waste material.

Used in conjunction with the PRO SORT intelligent sorting software and Remmert's PRO FMS production system, the new sorting solution is the key to achieving fully automated sheet metal working processes.

The FMS control center provides the connected laser machines with material for machining and issues production jobs.

An additional NC workstation can be easily integrated into the production control center for nesting purposes to ensure optimum cutting.

The FMS system then forwards all the relevant data to the robot's PRO SORT software, which automatically defines which part is set down where.

The key benefits of using the system are lower unit costs and production sequences that require little if any human input.

'Unlike other sorting solutions, the 'Laser-Sort 06' sorting robot is absolutely perfect for sorting both large and small items with absolute precision,' explained Matthias Remmert, managing director of the Remmert group of companies.

'The sorting system can handle sheet metal parts with a thickness of between 3 and 10mm and a weight of up to 300kg without any problems at all.' The items are picked up using a reliable process based on the use of pneumatic and magnetic standard tools.

Tools can be switched automatically using a tool changer.

Remmert will be presenting the new sorting solution at Stand B 58 in Hall 15.

Of course, visitors will also be able to obtain detailed information about the various storage solutions on offer from the logistics expert - from compact stand-alone systems for straightforward storage tasks through to complex sheet metal machining cells.

* Friedrich Remmert Datentechnik at EuroBLECH 2006, Hannover, Germany, October 24-28, Hall 15, Stand B58.

*About the Remmert Group - with approximately 400 systems installed in various sectors, the Remmert company group is one of the world's leading providers of storage technology.

Remmert provides tailored warehouse logistics solutions for sheet metal, long bars, pallets and small parts.

Its products and services range from individual, production-integrated solutions based on standard components through to complex total solutions for which Remmert, as the prime contractor, retains overall responsibility.

In addition, the logistics expert's range now also includes intelligent robot systems for the fully automated sorting of finished parts from sawing and laser machines.

Since as long ago as 1987, Friedrich Remmert and Friedrich Remmert Datentechnik (Remmert PRO for short) have together been offering complete one-stop solutions.

Each system is a perfectly tailored combination of storage technology, software and logistics know-how.

All systems are designed with a common objective in mind: increasing the efficiency of the customer's production sequences.

All of Remmert's process control and software systems can be easily integrated into the customer's existing software architecture - the company has had the necessary interface expertise at its fingertips for years.

From project planning and scheduling through design and installation and beyond to service, all Remmert products and services are one-stop solutions.

Existing customer structures and future development potential are taken into account right from the planning stage.

The company, which is based in Westphalia, offers worldwide 24h customer service for all its products.

This service is provided by in-house personnel.

Thick SS plates plasma-arc cut without dross

2006-12-26T02:41:00.000-08:00

Gas plasma-arc machine cuts 150mm plate thickness with a capacity of clean cut at 130mm, that means a smooth dross-free cut with bevel of less than 2 deg taper.

Arcraft Plasma Equipments (I) Pvt has designed manufactured and commissioned Gas plasma cutting machine for cutting 150 mm plate thickness with a capacity of clean cut at 130mm. By clean cut we mean a smooth dross free cut with bevel of less than 2 deg taper. The machine has been sold to Godrej, one of India,s largest manufacturers and fabricators, at their Vikhroli plant.

In fact, even the people at Godrej were not expecting a clean cut at 130mm as the the competitive quote received from foreign manufacturer specified a clean cut of 120mm that too using costly gas mixture of argon and hydrogen for cutting and nitrogen at high pressure and flow as swirl gas.

Arcraft has used cheap nitrogen gas at a pressure of only 2.5 bar and flow of only 23 litre/min to achieve the same.

The machine was designed , manufactured and supplied in a short period of only 45 days .

Last year Arcraft had achieved another first in India by selling three high tech keyhole plasma-arc welding systems to the same company which swung this order in its favour.

The 'beauty' of the machine is the concept of master slave where two 80mm capacity cutting machine work in parallel.

Independently these machines can be used as stand alone machine as both the machines have built in pilot arcing system.

The machines are built with conventional transformer/rectifier topology.

Each machine has four 100A transformers, each capable of cutting 20mm thick material.

The output power can be selected as 100, 200, 300, 400A by selecting combination of the transformers to cut MS/SS from 1 to 80mm.

Incase of 150mm cutting two such power sources are used in parallel where a concept of 'Master/Slave' is used.

In such condition the machines communicate with each other through PLC.

Any machine can be used as Master or Slave which can be selected by the operator.

The master controls full sequence of operation including cutting power and pilot arcing.

Slave only delivers the cutting power and the pilot arcing is inhibited.

Any combination of power, e g, 100A from Master and 200A from slave or 300A from master and 100A from slave etc can be adjusted.

The output current can be adjusted between 100 to 800A to cut 1 to 150mm of SS/MS.

Mazak's on the move in the north

2006-12-25T03:23:00.001-08:00

Yamazaki Mazak UK Limited has relocated its Northern Area office to larger and more convenient premises in Haydock.

After experiencing the many benefits of having a local presence to its northern customers for some 15 years Yamazaki Mazak UK Limited has relocated its Northern Area office to larger and more convenient premises in Haydock. The new address at The Parks, Haydock, is ideally positioned for easy access to the major industrial centres, thanks to its proximity to the intersection of the M6 (Junction 23) and the East Lancs Road (A580). 'Our ability to handle engineering projects from this regional facility has produced impressive results to date,' says Brian Robertson, Yamazaki Mazak's Northern Regional Sales Manager.

'This ability to communicate faster with customers and respond quickly to their requests for sales and technical support allows us to deliver more bespoke machine tool solutions.

'Being close to machine installations also allows us to support users during the important initial learning curve and to maximise production levels.

Relationships during this period form the basis for long term communication and experience transfer during the life of installation'.

Laser machining processes thicker materials

2006-12-25T03:23:00.000-08:00

The need to process materials whose thickness is outside the scope of its current manufacturing plant was the principal reason for Beakbane investing in its new Trumpf L3030 2D laser-machining centre.

The growing need to process materials whose thickness is outside the scope of its current manufacturing plant was the principal reason for Beakbane Limited investing in its new Trumpf L3030 2D laser-machining centre. Increased cutting speed was also another important factor in its choice. The company already has a Trumpf TC600L combination machine that provides laser cutting capability but its power is less than half that of the new flatbed addition.

With a 3.2kW laser the L3030 has the potential to boost its production significantly.

With almost 50 years experience in designing and manufacturing protective covers in steel and flexible materials for production machinery, Beakbane supplies components to machine tool builders worldwide.

Products include steel telescopic and folded covers, armoured aprons, roller blinds and slideway wipers.

The company has also developed new projects away from its core business.

For example it now manufactures its own range of food and drink trolleys used in hospitals and other public service areas.

'The L3030 is replacing our TC240R punch press that we bought in 1989,' explained Barry Reeves, Managing Director.

'That machine revolutionised the way we processed our metalwork and it was followed seven years later by the TC600L combination machine that is still going strong today.' The installed L3030 is to become Beakbane's main cutting facility with the TC600L as back-up and for parts requiring additional forming.

'These account for 30% of cutting capacity and together the machines will provide almost 100% of our component needs,' Mr Reeves adds.

The flexibility of the L3030 to cut Beakbane's thinnest 0.5mm stainless through to 20mm mild steel will be commercially advantageous across all its market sectors.

So too will its ability to process cost-effectively any batch size from one-offs to several hundred; the laser will also allow customer part numbers to be marked.

Beakbane will operate a twin shift basis and although the company has no plans for lights out production at present, the modular design of the machine enables it to keep its options open on future automation.

'This is proven technology,' Mr Reeves concludes.

'We know we're getting a quality product and the fact there are so many Trumpf machines in the marketplace underlines this view.'

Minimise laser head/workpiece collisions

2006-12-24T03:22:00.000-08:00

A collision protection for laser processing is based on a magnetic coupling between the laser head and the machine, keeping force from being applied in any of three axial directions.

An innovative solution from Trumpf will minimize collisions between the laser head and the workpiece. The collision protection for laser processing is based on a magnetic coupling between the laser head and the machine, keeping force from being applied in any of the three axial directions. If the workpiece should come into contact with the laser head during laser processing, the contact is broken off in fractions of a second - before damage can occur to either the workpiece or the laser head.

A special highlight: After the incident, the head, secured with a plastic strip, is quickly reattached and the machine is ready for operation without having to be recalibrated.

The high precision afforded by a three-point harnessing and a stable connection between head and machine using permanent magnets and electromagnets are substantial features of this new solution.

One laser head CNC cuts all thicknesses

2006-12-24T03:21:00.000-08:00

A flatbed CNC laser cutting and profiling machine - introduced at EuroBLECH - uses one cutting head to cut all thicknesses and there is also an optional nozzle exchanger.

The new flatbed laser machine, TruLaser 5030, the heir to the Trumatic L 3050 (TruLaser 5030 classic), is clearly superior to its predecessor with improved processes, greater dynamics and less unproductive time. The highlight of the TruLaser 5030 is the single cutting head strategy. Thanks to newly designed beam guide and cutting head interface, all sheet thicknesses can now be processed using the same cutting head: The machine automatically changes the laser beam depending on the material to be processed - no need to switch the head.

That's especially helpful for automated operation with various materials.

Even without automation the one cutting head strategy reduces downtime.

And with the optional nozzle exchanger there is no need to manually exchange the nozzle.

The integrated collision protection protects the cutting head from damage: The cutting head folds away during a collision.

It can also be returned to its place using a handle thanks to the intelligent cutting head interface.

The cutting head automatically reassumes the correct position in case of small collisions.

A further benefit of the TruLaser 5030 is the new FastLine process.

It optimizes the entire cutting action ensuring maximum economy: Processing times can drop by up to 50% in thin sheets.

The new process also reduces slag residue on the top of sheet metal.

The proven TruFlow 6000 laser is almost maintenance-free thanks to a magnetic bearing radial turbine blower.

The 6kW laser with radio-frequency excitation guarantees the best beam quality.

The power can be regulated as needed.

The LiftMaster Store supplements the TruLaser 5030.

It automatically loads and unloads the machine and deposits the sorted, finished parts - all with direct storage connection.

Finished, cut sheets and parts can be reliably re-stored as can scrap skeletons.

In the LiftMaster Store Linear extension the vacuum frame and rake can be moved in linear fashion.

High speed plasma-arc profiler described

2006-12-23T04:01:00.002-08:00

Literature describes a high performance, competitively priced high speed plasma cutting machine, which offers an option for oxy-fuel cutting.]

New literature has been published on ESAB Automation's Combirex CXL-P CNC cutting machine. This is a high performance, competitively priced high speed plasma cutting machine with an option for oxy-fuel cutting. It is a modularly designed heavy duty portal machine for high productivity and can be supplied with a variety of plasma cutting systems for material thicknesses 1-40mm.

It can also be supplied with up to four oxy-fuel cutting heads for cutting even thicker material.

The Combirex CXL-P has a powerful three axis drive system that delivers speeds up to 20,000mm/min.

The transverse master drive carriage is guided by a linear guiding rail and driven by a rack and pinion planetary AC drive.

The longitudinal drive is by twin rack and pinion AC drives.

This design ensures a smooth machine motion with rapid acceleration for higher part tolerance and quality.

The Combirex CXL-P is supplied with ESAB's Vision LE CNC controller, a high performance PC based control designed for fast and easy use.

Along with the graphics, it shows the outside dimensions of the part and gives the operator control for the required area needed to cut the shape.

Power tool removes laser cutter slat bed slag

2006-12-23T04:01:00.001-08:00

Removing slag produced during laser cutting from the support slats in the machine beds need no longer be laborious when using a low power hand tool.

Just last year it was still quite laborious to remove the slag produced during laser cutting from the support slats of systems. With the award-winning power tool TSC 1 from Trumpf that's no longer the case: Any necessary cleaning can now be done quickly and without using a lot of power. The TSC 1, used to clean laser cutting systems and presented for the first time by Trumpf at the Munich Handicraft Tradeshow, Germany, in March 2006, was successful 'right off the bat'.

Market developments along with being awarded the 2006 Federal Prize for Innovation both confirm this fact.

Werner Cloos, director sales and marketing, Power Tool Division, at Trumpf reported that: 'The success of the TSC 1 is phenomenal'.

'Since its launch, we have seen extremely high demand throughout.

Users have been waiting for exactly this kind of device.' That's no surprise because the Trumpf TSC 1 solves a problem that is unavoidable when operating flatbed laser machines: When metal workpieces are processed, slag is produced that collects on the support slats of pallets.

Sometimes the growing slag thickness reduces the quality of the workpieces because the laser can no longer make the usual clean cuts.

To clean the support slats in the past, it was usually necessary to use a hammer or a similarly heavy tool which took several hours and was difficult, dirty work.

'Many companies change the support slats, which is unnecessarily expensive because the slats are washed about five times,' added Cloos.

The TSC 1 slat cleaner from Trumpf solves this problem.

A standard-sized pallet of 1500mm x 3000mm can be cleaned in about only 20 minutes with this tool and requires very little power usage.

All operators have to do is put it on a slat row and switch it on.

The device then automatically removes the collected slag from the slat, moving forward by itself.

A sliding block ensures that the guiding is secure.

Operators simply keep the TSC 1 on track.

Because vibration is minimized, the device is easy and pleasant to use.

A stripper sheet removes slag that is stuck and won't fall off on its own.

If a slat is clean the device is put on the next slat until the entire pallet of the machine is cleaned.

By working so quickly, the Trumpf TSC 1 pays for itself in no time because it costs only about one-fourth of the cost of exchanging the pallet.

Compared to manual cleaning, the cost is still about two-thirds lower.

The slat cleaner can in principle be used with any flatbed laser machine equipped with a pallet changer.

Not only was the cleaner tested in every Trumpf model, but it has performed well with competitors' machines in practice.

It is rarely necessary to dismantle the support slats.

Usually it takes place parallel to the uptime without any preparation.

Cloos was asked: 'Mr Cloos, you introduced the TSC 1 slat cleaner in March 2006'.

'What has been the result in terms of demand?' Cloos replied: 'Interest in the device was very high from the very beginning and even after over a half-year it has not let up at all.

Apparently, users were waiting for this kind of work relief.

Which actually doesn't surprise us because we are familiar with the slag problem from our own experience.

Since its launch, we have seen very high demand throughout and are working furiously to serve all of our customers.' How did the idea for the TSC 1 actually come about?

Cloos answered: 'As I suggested, we were already familiar with the problem from our own experience.

Slag on the pallet slats can lower parts quality, so it has to be removed.

But there was never any fast, cost-effective solution'.

'Using tools such as hammers or pneumatic chisels made cleaning slow and exhausting.

The frequent practice of exchanging the slats was very expensive.

We discussed a lot of possible solutions in-house and with the TSC 1 ultimately built a tool that meets all requirements in terms of ergonomics, thoroughness and economy.' What are the most important features of the tool from the user's perspective?

Cloos said: 'The greatest advantage is probably its ease-of-use.

The user doesn't have to adjust anything because the TSC 1 automatically adapts to the slag thickness.

The same is true of the forward motion.

Benefiting from the guidance provided by a slide block, users of the TSC 1 have a tool with which hardly anything can go wrong and which is pleasant to use because of minimal vibration.' Do the support slats have to be removed for cleaning and can the TSC1 also be used for flatbed laser machines made by other manufacturers?

Cloos said: 'Removing the support slats is almost never required.

We have tested the tool in all of our models, even older machines.

Of the approximately 20 Trumpf machines in recent years only the TC L 2510 requires that the slats be dismantled.

But then again the work is quite a bit faster than with other tools.

Furthermore, we know that the TSC 1 is regularly used without any difficulty in the machines of all our significant competitors.' * About the Power Tools business division of Trumpf - sheet metal processing power tools have a long tradition at Trumpf.

As early as 1934 the company from Ditzingen, Germany, presented the first motorized handheld shears for cutting sheet metal, thereby laying the foundation for the entire corporate group's 'sheet metal competence'.

Ever since, the sheet metal specialists have been constantly developing professional power tools - in addition to stationary machines for punching and forming, laser processing and bending - and as leaders of innovation they have set the pace in this area as well for changing market requirements.

During fiscal year 2005/06 the Power Tools business division of Trumpf, which has had its headquarters in Gruesch, Switzerland, since 1980, recorded EUR 72 million in sales revenue with 255 employees.

The current product range includes power tools for cutting and connecting sheet metal and for forming welding edges.

Plate-cutting programming saves 7% materials

2006-12-22T03:14:00.000-08:00

An optimized programming system enables easier, more effective and cost-efficient design of thermal cutting processes in industrial plate profiling and cutting - saving 7% materials.

Up to 7% less material consumption, significantly lower plate handling requirements and lower item costs - the optimized COLUMBUS programming system enables easier, more effective and cost-efficient design of thermal cutting processes in industrial plate processing and machining. At the euroblech 2006 exhibition stand of ESAB, visitors could convince themselves of the speed and ease with which the users can design their own individual cutting and marking programs with COLUMBUS. Installation of COLUMBUS on a PC running Windows (95/98, ME, NT and 2000) is a 'cinch' (easy - Ed), and the programming system can be integrated into existing EDP structures easily via PPS.

This enables, for example, accurate import and export of existing parts lists and calculation data.

User friendliness is additionally enhanced by the new graphical design of the user interface, with a clear organization and largely self-explaining symbols.

To support automated cutting processes, this programming system is open to all applications for central process control and was designed such that the customers can specifically select the software modules they actually need.

This reduces initial costs and the system can be adapted to changing requirements quickly.

COLUMBUS can be used for converting drawing data in machine-readable CAD data, for nesting and inserting cutting parameters as well as for plate management.

With the new nesting system, the cutting specialists of ESAB Cutting Systems from Karben near Frankfurt am Main, Germany, succeeded in increasing material utilization in plasma-arc, flame and laser cutting even further.

COLUMBUS is a sophisticated, flexible and intelligent tool with which the users can easily create their own NC cutting programs.

Bevel head produces precise 3D plasma-arc cuts

2006-12-22T03:13:00.000-08:00

A bevel head serving as a carrier and guide of the plasma-arc torch is used for precise and variable bevel and section cutting of three-dimensional parts.

Visitors of the recent euroblech 2006 exhibition stand of ESAB Cutting Systems were given the opportunity of convincing themselves of the impressive flexibility of the innovative VBA-Wrist bevel head. It serves as a carrier and guide of the plasma-arc torch and is used for precise and variable bevel and section cutting of three-dimensional parts. Typical applications include arc cuts in tank and boiler construction (dished boiler ends), tube cutting as well as all common contour cuts.

With the VBA-Wrist, the plasma cutter can be moved, fully automatically and program-controlled via AC servo motors, in five axes and positioned exactly.

When combined with the ESAB Vision controller, even the tightest bevel tolerances can be realized according to the manufacturer.

Thanks to its compact designs and low weight, the VBA-Wrist can be used with almost any machine size The function of VBA-Wrist follows a completely new, patented principle.

In contrast to conventional systems, the tool centre point (TCP) remains fixed in space during swivelling.

The integration of VBA-Wrist into a CNC machine system allows for an uncomplicated control all cutting tasks, including bevel cutting.

The cutting parameters are automatically set for various material thicknesses and bevel angles.

Completely integrated process parameters ensure a smooth cutting process.

Exactly repeated cycles in bevel cutting for Y- and X-cuts provide highest cutting quality, even for complex geometries.

With the software packages specially developed by ESAB, it is even possible to create complex and individual NC cutting programs quickly and easily.

The anti-collision plasma torch system and the integrated tactile height setting system of VBA-Wrist reduce maintenance requirements and adjustment work to a minimum.

Now, ESAB Cutting Systems also offers the system in combination with a cameral-based plate position monitoring system.

Visual control via the control panel display makes tedious adjustment at the workpiece unnecessary and the user is always kept updated on the current state of the wearing parts at the torch.

With the VBA-Wrist, ESAB has developed a marketable and practical solution for industrial cutting tasks which, so far, mostly required the use of expensive robots.

Plasma-arc update speeds metals cutting, profiling

2006-12-21T03:13:00.001-08:00

Plasma-arc plate profiling and cutting system achieves cutting speeds of up to 35m/min for fast production cuts and can make highly accurate, sharp-edge precision cuts.

At the recent euroblech exhibition in Hannover, Germany, the cutting specialists of ESAB Cutting Systems from Karben near Frankfurt/Main gave an impressive presentation of what state-of-the-art plasma technology can achieve today. A combination of the flat-bed machine Eagle, the m Plasma system and the Vision 55 controller demonstrated that high-speed and high precision are no longer antonymous parameters. With m Plasma, ESAB succeeded in improving this efficient, energy and wearing part saving cutting technique significantly.

With m Plasma, impressive cutting speeds of up to 35m/min can be realized.

What makes the system particularly special is the fact that the user can perform both fast production cuts and highly accurate, sharp-edge precision cuts using one and the same tool and without having to replace any wearing parts.

m Plasma can be used for plate thicknesses up to 150mm, efficient, fast productions cuts can be performed up to 50mm.

Punching is possible up to 40mm.

The best results as regards the cutting quality are obtained when m Plasma is used for cutting carbon steels.

In this case, the cutting edge is almost rectangular and forms a perfect burr-free weld edge.

Another advantage of m Plasma is that the user can even mark the workpieces without having to replace the torch, by simply changing the corresponding parameters on the central control panel.

All processes of the cutting plant presented are controlled by the Vision 55 controller featuring the real-time operating system Windows CE 5.0 NET and ESAB's COLUMBUS programming system.

The all-inclusive solution is completed by an integrated drilling device as well as a camera-based visual monitoring system for exact alignment of the plates on the cutting bed.

Said Soeren Carlsson, sales manager Germany at ESAB Cutting Systems: 'The cutting plant presented at EuroBLECH, featuring the Eagle and m Plasma as the basis of the system, clearly reflected the current trend, i e, higher efficiency by linking different work steps in one complex machine concept which can be adapted specifically to meet the customer's individual requirements.'

Plate processing centre doubles throughput

2006-12-21T03:12:00.000-08:00

An innovative plate processing centre is equipped with two flame cutting units and has options of plasma-arc cutting and can be equipped with carbide drills, reducing drilling times by about 30%.

The innovative plate processing centre KF 2512 of Kaltenbach increases the efficiency by up to 100%. While the other plate processing centres of Hans Kaltenbach Maschinenfabrik in Loerrach, Germany, have one flame cutting unit, the new KF 2512 is equipped with two flame cutting units. They allow the production of two identical parts in just one pass.

The plate processing centre KF 2512 presents the latest and biggest machine within the KF series.

It is developed to meet the special demands of the steel construction and steel service centres.

It is the perfect machine for the efficient drilling and flame cutting of steet metal and flat steel.

The working range of KF 2512 starts at plate dimensions 220 x 500mm up and goes up to 2500 x 6000mm.

Beneath the impressive increase in efficiency the use of the innovative Kaltenbach machine produces further advantages.

First to mention is the optional plasma-arc cutting unit.

Compared to a autogenous flame cutting unit the plasma-arc unit saves about 80% of the processing time.

Furthermore the KF 2512 can be equipped with carbide drills, reducing drilling times by about 30%.

The hard marking process takes up just approximately one second per character or number.

Additionally the plate processing centre is equipped with an AutoSorter for fully automatic, operator-free handling.

Like the other KF models the tool changing at the KF 2512 is realised automatically.

Two tool changing units with six magazine positions for different drill sizes.

The tool changing device consists of a disc tool magazine which is arranged directly adjacent to the drill carriage.

The modern steel fabrication specific software package CIM-PLATE is used for program setting of the machine control.

The program running under Windows XP Professional ML processes the input workpiece data and generates the NC-program for the plate cutting and drilling centre.

Bevel head plasma-arc torch does edge-preps

2006-12-20T22:41:00.000-08:00

Plasma-arc cutting and profiling machine has a bevel head that allows profiling and edge preparation on plate profiles to be carried out simultaneously and accurately.
Afon Engineering of Swansea, UK, is a fabricator that specialises in cutting, profiling, rolling, bending and forming plates from materials up to 50mm thick. Typical contracts include pressure vessels, bridgework, offshore skidwork and pipework. Whereas parts were previously guillotined and manually cut with gas cutting equipment, the company has now purchased an ESAB Suprarex precision plasma cutting machine - which has transformed the business, such is the improved productivity and accuracy.
The Suprarex machine is unusual in that it has an ESAB 200A precision plasma-arc cutting torch mounted on a bevel head that enables profiling and edge preparation to be carried out simultaneously.
Not surprisingly, this makes a substantial difference to how quickly plates can be prepared.
The exceptional accuracy also helps to streamline the production of fabrications as well as being beneficial to Afon Engineering's customers.
Furthermore, the same plasma head can be used to mark the plates so that other components can be positioned ready for welding.
Again, this saves a considerable amount of time.
Yet another time saving is achieved by using the machine to stitch-cut apertures prior to the plates being rolled, which reduces the amount of manual gas cutting that is required later.
Because of the varied nature of the work undertaken by Afon Engineering, the Suprarex machine is called upon to cut a wide range of materials in thicknesses from 1mm to 30mm on plasma-arc (a maximum plate thickness of 50mm can be plasma cut if required).
It also features gas cutting with the option of straight line bevelling heads for thicker materials upto 150mm.
Materials processed include mild steel, boiler plate, stainless steels, Hastelloy, chrome moly, inconel and titanium - in plate sizes up to 12 x 3.5m.
In addition to the cutting machine and control system, Afon Engineering also bought ESAB's Columbus nesting software that has enabled savings to be made through increased material utilisation.
In conjunction with the materials database held on the machine's controller, this software makes it quick and simple to set up each job on the machine, with very little risk of operators making any errors.
Andrew Beaujean, the sales engineer at Afon Engineering, was extremely pleased with the machine saying: 'It really is phenomenally quick.
Compared with the way we worked before, the machine prepares plates five or six times faster, and with better accuracy.
Taken as a whole, the faster cutting, edge preparation, stitch-cutting, marking, nesting software, materials database and high accuracy has transformed our business.' In addition, he was also complimentary about the level of service from ESAB: 'When we were talking to various suppliers prior to making a final decision, ESAB was more helpful than the others.
We also liked the way ESAB stocked spare parts in the UK or could get them delivered quickly from Germany.' Beaujean concluded: 'The machine was a good price and has proved to be reliable, too.

Lower cost laser does 80% of cutting/profiling

2006-12-20T22:40:00.000-08:00

Compared with other high quality laser cutting machines, a customer can invest in a machine at around half the investment cost, and process some 80% of the spectrum parts.
Bystronic UK has launched the ByVention laser cutting system. The ByVention is not only a completely new laser innovation but also a new business model for the Bystronic Group and the industry in general. The ByVention has been designed to meet the needs of the market.
A theoretical survey showed that approximately 80 per cent of all parts cut by laser cutting machines are processed using a sheet thickness of a maximum of 8mm and in size 500 x 500mm.
However, the ByVention has a cutting area of 1562 x 772mm and is equipped with a 2.2kW resonator which allows a maximum sheet thickness of 4mm for aluminium, 6mm for stainless steel and 8mm for mild steel.
Compared with other high quality laser cutting machines, a customer can invest in a machine at around half the investment cost, with which they can process some 80% of the spectrum parts.
The machine is easy to operate and as a result training time is reduced to a minimum.
This is achieved as the ByVention is operated via pre-defined programs and cutting parameters using a touch screen.
New operators benefit from the simple and logical operation and after a short period of training are familiar with the control and its integrated function and are able to operate the machine to its full capacity.
A further highlight of the ByVention is its compact design, which makes it the smallest laser cutting machine for standard-sized metal sheets.
The machine requires just 6 x 6m of floor space and therefore customers can utilise even the smallest of spaces.
The control cabinet and the system's laser source are integrated in the machine frame and form a single unit.
Additionally, the cooling unit and the used air filter have been combined in a compact, powerful unit.
The operating area of the ByVention is completely accessible and the user does not have to worry about photo-electric barriers thanks to the machine's integrated safety system.
Due to the compact design, the laser beam is kept short and is therefore for high precision cuts.
The ByVention is equipped with an innovative Bystronic designed materials flow concept, which makes all parts instantly available and ensures flexibility when using various sizes of material and partially used sheets.
Cut parts are continuously and automatically transported from the cutting area and are immediately available to the user even during the cutting process.
The removal area is fully accessible; therefore removal of cut parts is simple and convenient.
The cutting area is also readily accessible from the front via a large sliding door.
The new processing concept makes a shuttle table unnecessary and it can be used with various European and US American standard metal sheet formats (patent registered).
When the machine was designed emphasis was placed on rapid and easy service.
The machine is covered by a two-year Bystronic warranty as well as two years preventive maintenance.
This ensures high reliability of the machine and avoids expensive repairs.
The highest quality control standards during the manufacturing process and the fact that the ByVention, like all Bystronic machines, is built for round-the-clock operation and a long life span ensures maximum reliability and a high re-sale value of the machine.
The cost of the ByVention also includes the Bysoft CAD/CAM software package, commissioning and basic training as well as the two year warranty and preventive maintenance.
The machine is offered at a fixed price.
Thanks to the 'everything included' concept, the customer knows exactly what the investment costs are.
This latest concept in laser cutting will appeal to a wide range of customers.
Companies that already use laser cutting machines and require additional capacity for standard size sheets can extend their added value for a reasonable price.
An increased added value can also be achieved by companies who wish to negate the need for external sub-contractors and bring jobs in-house.
The machine is economical even in single-shift working.
Relatively low investment costs make the ByVention a viable prospect not only for new users of laser technology but also for companies that have limited capital available or are planning to invest in a second-hand machine.
It is also a fist choice where space is at a premium.
Also original equipment manufacturers that produce a large number of standard sized parts can profit extensively from a ByVention.
The ByVention is not just a new machine and operating concept.
Far more, this highly efficient laser cutting machine is also a new business model.
This includes the fact that the ByVention is sold at a uniform price worldwide.
The net price, to which only taxes and customs duty have to be added, means that no variations or additional options are offered.

Waterjet software adjusts cutting automatically

2006-12-19T22:39:00.000-08:00

Waterjet cutting control software automatically adjusts for cutting speed and material thickness and can improve cycle time performance up to 35% and optimise cutting speeds.
Flow, the world's leading developer and manufacturer of ultrahigh-pressure (UHP) waterjet technology equipment used for cutting, cleaning (surface preparation) and food safety applications, just launched FlowMaster 6.0, FLOW's innovative Windows-based waterjet control system. FlowMaster software is now even easier to use and more powerful than ever before. * The system's new features give operators the ability to do the following.
Improve cycle time performance up to 35%.
Program and cut parts with varying thicknesses with programmable Z-axis capability.
View and path parts in full 3D for easy design.
Optimize cut speed for part corners to reduce cycle time.
Improve edge quality through the ability to control cut speed to reduce marks on parts.
Save time through automatic calculations - there's no need to stop and manually calculate and adjust the settings.
Reduce the number of operational steps and increase output.
Enhanced file support including dxf for AutoCAD 2004.
'Waterjet software is evolving to help solve the challenges faced by manufacturers,' said Robert Peterson, Flow's waterjet market manager.
'With Flow's innovative software, waterjet operators are no longer restricted to cutting only on the X-Y plane, and can easily design and cut parts never imagined on a waterjet with varying height and thickness.
In addition, FlowMaster 6.0 will help customers lower cost per length on projects through the software's ability to improve cut speed and thickness.' * About Flow - with more than 30 years of experience and more than 9,000 installations FLOW is the world market leader in the development, design, and sales of ultrahigh-pressure pumps and complete waterjet and abrasivejet cutting systems for processing a wide variety of materials.
Flow Europe is a subsidiary of Flow International Corporation, USA, and the European Headquarters for all products relating to ultrahigh-pressure waterjet cutting technology.

Contour follower avoids waterjet collisions

2006-12-19T22:38:00.000-08:00

Height and collision sensor for waterjet and other cutting processes increases efficiency and accuracy by maintaining optimal cutting distances and preventing cutting head impacts.
Dynamic contour follower avoids waterjet collisions Height and collision sensor for waterjet and other cutting processes increases efficiency and accuracy by maintaining optimal cutting distances and preventing cutting head impacts. Flow, the world's leading developer and manufacturer of ultrahigh-pressure (UHP) waterjet technology equipment used for cutting, cleaning (surface preparation) and food safety applications, introduces its new Dynamic Contour Follower (DCF), designed to increase efficiency and accuracy by maintaining optimal cutting distances and preventing cutting head impacts. The DCF is a key component of an abrasive waterjet system in helping customers achieve superior cut quality and part accuracy by maintaining perfect stand-off height.
Whether the waterjet is cutting at perpendicular or in dynamic mode with an angle, the DCF allows for automatic set and track of the stand-off distance between the mixing tube tip and the material being cut.
If the DCF senses a change in material contour, the Z-axis vertical position adjusts to avoid crashing.
The DCF is designed to work in conjunction with the PASER ECL Plus cutting head system and Dynamic waterjet cutting heads.
The DCF is ideal for job shops and metal service centers, needing to cut precise parts in a cut quality that is independent of height variation, or applications that require extra protection when cutting material is warped, stacked, stressed (such as tool steel), or slightly curved.
'The DCF will help users improve their operations by increasing machine uptime and operator productivity since the DCF senses material variations and continues cutting by automatically adjusting around it,' said Andreas Meyer, technical director of Flow Europe.
Flow's ultrahigh-pressure waterjet shapecutting systems have become the global 'machine technology of choice' for many applications.
Flow's abrasive waterjet cutting systems are ideally suited for cutting a variety of materials ranging from stainless steel and aluminium to titanium, Inconel, composites and even stone and glass.
Flow waterjet systems can cut virtually any material up to 254mm (10in) thickness with accuracies down to the range of some tenth millimetres depending on material and complexity of contour.
* About Flow - with more than 30 years of experience and more than 9,000 installations Flow is the world market leader in the development, design, and sales of ultrahigh-pressure pumps and complete waterjet and abrasivejet cutting systems for processing a wide variety of materials.
Flow Europe is a subsidiary of Flow International Corporation, USA, and European Headquarters for all products relating to ultrahigh-pressure waterjet cutting technology.

Dynamic waterjet system cuts accurate parts

2006-12-18T22:37:00.002-08:00

An innovative dynamic waterjet system with active tolerance control produces more accurate parts at significantly higher cutting speeds than parts cut with a conventional waterjet.
Since the introduction of Dynamic Waterjet Flow was able to further strengthen its world market leader position in waterjet cutting. Tremendous cost advantages and cut part quality improvements are not the only reasons for this successful business development. The high flexibility and the easy handling add to the reasons why customers decide in favour of Flow systems.
The innovative Dynamic Waterjet system with Active tolerance Control produces more accurate parts at significantly higher cutting speeds than parts cut with a conventional waterjet.
Dynamic Waterjet utilizes a newly-developed advanced motion system that incorporates unique mathematical cutting models, which control a small, articulated wrist that is attached to the waterjet cutting head.
This wrist allows the cutting head to tilt in any direction, compensating for the stream lag and taper experienced with conventional waterjet cutting machines.
Stream lag and taper are a natural, but undesirable, result of cutting with a beam-type cutter such as a waterjet.
The faster parts are cut, the greater the stream lag.
Stream lag causes part geometry errors.
In addition, as cut speed is increased through a given material, the waterjet beam produces ever-increasing taper.
Conventional waterjets must slow down in order to reduce or eliminate finished-part tolerance errors caused by stream lag and taper.
Now, with Dynamic Waterjet, these limitations are overcome.
Summary of Dynamic Waterjet advantages.
Significantly improves cut part geometry and tolerances (+/-0.05mm under optimal conditions possible).
Cuts parts 25-300 % faster than conventional flat stock waterjet cutting machines.
Virtually eliminates taper.
Reduces cost per part by up to 75%.
True part stocking ability with consistent tolerance layer to layer.
Cuts a variety of materials, such as metal, stone, glass, and composites.
Easy to use and easy to program.
Dynamic Waterjet is available for both of our machine types, the Waterjet machining center (WMC2) and the Integrated Flying Bridge (IFB2).
* About Flow - with more than 30 years of experience and more than 9,000 installations Flow is the world market leader in the development, design, and sales of ultrahigh-pressure pumps and complete waterjet and abrasivejet cutting systems for processing a wide variety of materials.
Flow Europe is a subsidiary of Flow International Corporation, USA, and the European Headquarters for all products relating to ultrahigh-pressure waterjet cutting technology.
Flow Europe has subsidiaries in France, Italy, Spain, and UK.

Waterjet profiler offers versatile cutting

2006-12-18T22:37:00.001-08:00

Water jet cutting and profiling machine s ideal for high-production, high-speed cutting, as well as the low production rates and high job variations.
On the occasion of the recent EuroBLECH, in Hanover, Germany, Flow presented the WMC2 Waterjet Machining Center, the next generation of the successful WMC series. The WMC2, designed by a worldwide team of multi-disciplined Flow employees and customers, is ideal for high-production, high-speed cutting, as well as the low production rates and high job variations commonly found in job shops. Through its flexible and fully modular design customers can equip the Waterjet machining center to meet a myriad of individual needs now and in the future.
* WMC2 offers even higher productivity - in the growing Europe today's cutting systems need to be very flexible.
In order to meet customer requirements now and in the future and to guarantee high productivity the WMC2 has been designed.
With its new electric and software the WMC2 offers higher cutting speeds and thus faster cycle times.
The WMC2 is much more flexible, versatile and easy to use compared to other cutting processes, such as laser or punch.
Also compared to conventional waterjet systems the Waterjet Machining Center WMC2 offers higher productivity.
Furthermore the user benefits from the sophisticated design and up to date manufacturing processes that reduce maintenance requirements.
'The WMC2 is an amazing waterjet machine that we are extremely proud to introduce to the market,' said Andreas Meyer, director of Product Development X-Y Systems at Flow Europe.
'The WMC2 improves upon what was already the most technologically advanced waterjet in the world, and is one machine customers will be proud to have on the shop floor.' * Additionally, the new Waterjet Machining Center features.
Faster part cutting cycle times.
Streamlined operation.
Enhanced ergonomics with features such as a roll around cabinet.
For the utmost in cutting control, it is available with either the latest generation of FlowMaster PC or Siemens CNC control.
The machine's modular design means the WMC2 can be equipped with variety of Intensifier or HyPlex pumps and cutting heads so customers can select the right pump and number of cutting heads for their appli-cation today and upgrade later should their needs change in the future.
Optional multi-head PASER ECL Plus cutting system or dual head Dynamic Waterjet capability for high productivity.
'Through the WMC2, we've developed the fastest and most flexible waterjet system on the market today,' said Michael Sienz, general manager of Flow Europe.
'Our goal is to keep our customers competitive now and into the future, and the WMC2, with its simplicity, high reliability, and ease of use, is designed to do just that.' With more than 30 years of experience and more than 9,000 installations Flow is the world market leader in the development, design, and sales of ultrahigh-pressure pumps and complete waterjet and abrasivejet cutting systems for processing a wide variety of materials.
Flow Europe is a subsidiary of Flow International Corporation, USA, and the European Headquarters for all products relating to ultrahigh-pressure waterjet cutting technology.
Flow Europe has subsidiaries in France, Italy, Spain, and UK.

CMS UK now offers waterjet cutting systems

2006-12-17T22:36:00.000-08:00

Tecnocut waterjet CNC cutting systems - with hundreds of systems installed worldwide - are now available from Nottingham based company CMS Group UK.
Tecnocut established in 1992 are specialists in the design and manufacture of CNC waterjet cutting systems with many hundreds of machines installed worldwide. * Mutual Benefits - CMS a large Italian company specialising in the design and manufacture of a range of sophisticated 5-axis CNC machining centres for a wide variety of applications. Further enlargement of CMS came in 2005 when Tecnocut joined the group.
Mutual benefits from the merge ensure Tecnocut have the opportunity of benefiting from the CMS global distribution network, with 25 branches operating in 120 countries world wide, whilst CMS are able to integrate the Tecnocut waterjet technology into some of their larger five axis machines typically used in the automotive and aerospace sectors where larger Z-axis clearance and articulating robictic cutting head is required * Specialist company - waterjet cutting system consists of three parts: pressure intensifier, working table and a CAD-CAM programming system.
Tecnocut can boast of being the only manufacturer in Italy who designs and produces the entire system in house.
The pressure intensifier is the heart of the waterjet cutting system, Tecnocuts Jetpower system consists of parallel, synchronized and independent pressure pumps that assures: a more constant and steady pressure level.
Various units are available ranging from 60hp-120HP.
* Applications - the success of the waterjet machine is its amazing flexibility without complex change over the machines can process almost any material, typically metal and metal alloys, brass, copper aluminum as well as glass and stone based products.
Set up time is further reduced as the system requires very little in the way of clamping of the raw material

Dynamic laser cutters reduce production costs

2006-12-17T22:35:00.000-08:00

A drastic reduction in production costs and times is being achieved with a laser profiling and cutting machine equipped with a highly dynamic, lightweight head.
Effectively two machines in one; the Syncrono incorporates a highly dynamic and ultra-lightweight head integrated with a machine with a large operating envelope, both of which are perfectly coordinated to optimise processing times. With the highest dynamics applied to the smallest masses, this concept achieves extreme performance, excellent cutting quality and reduced running costs, while active compensation of masses and control algorithms ensure smooth and vibration-free motion. The result is a machine that guarantees hitherto unimaginable processing times; 6G acceleration enables more than 1000 holes to be cut in a minute, twice that of other laser machines currently on the market.
The flexibility and quality of laser cutting has allowed a continuous and steady growth of the laser machines sector during the past decade.
Plasma-arc cutting and punching are no longer the undisputed leaders, as the laser has become the leading technology in the sheet metal cutting field.
Today's market requirements are forcing manufacturers towards solutions that not only provide excellent quality and great flexibility but also high cutting speed and therefore, greater and greater productivity.
Syncrono is Prima's answer to this market need.
Machine, laser, CNC and electromechanical parts are all integrated in a compact, modular structure that is easy to transport and which does not require machine foundations.
The bed is manufactured from synthetic granite, while aluminium carriages ensure high mechanical stability and rigidity.
The machineandsup1;s key features include the following.
* Flying optics: providing speed and precision, irrespective of the gauge of metal being processed.
* Compact design and easy installation: machine foundations are not required.
* Modular construction: choice of a large number of configurations plus flexibility to meet future production needs.
* Application versatility: the rapid adjustment from 5 to 7.5in optics enables a wide variety of different materials and thicknesses to be processed.
Syncrono also features independent and programmable control of the focal position and an active workpiece collision avoidance system.
The innovation of Syncrono is its fusion of two synchronised machines; an ultra-lightweight and super-fast head providing 'micro' level movements, effectively mounted on a 'macro' machine with a large working area.
Both mechanisms are coordinated by algorithms that automatically control the local axes of the head and the main axes of the machine.
The local axes perform 'micro' movements (to cut holes, corners, small shapes, or paths with frequent changes of direction), while the main axes carry out 'macro' movements (for contours, large shapes, etc).
The 'micro' and 'macro' movements are undertaken simultaneously, like those of a human hand and arm when writing or playing a keyboard.
The numerical control, like the human brain, synchronises them in order to ensure continuous, rapid and coordinated movement.
The focusing head utilises parallel kinematics with direct drives to achieve more than 6G acceleration during cutting cycles.
Syncrono performs even the most complex paths with unrivalled cutting quality and speed.
Typically, high dynamic laser machines use direct drives in all axes.
However, their combination of large mass and rapid movement make them prone to vibration.
By contrast, Syncrono uses direct drives only for the micro carriage, dramatically reducing vibration.
Reliability and accuracy are through an active anti-vibration system, which minimises impulsive stress on the machine's structure.
The machine's design ensures a constant length optical path throughout its cutting cycle - for high precision and repeatability across the machine's entire working range.
Syncrono is offered with Prima's fast axial flow CP 4000 or new CV 5000 laser.
The company's latest generation of CV lasers utilise magnetic bearing turbines, solid state high voltage power units and servo-controlled gas mixing to enable high powers to be achieved with maximum efficiency.
Syncrono is designed throughout for maximum operational efficiency.
* The worktable is divided into segments for optimising fumes extraction and its pallet for holding 2D workpieces.
* Wheeled scrap collection drawers provide fast and easy movement.
* Polycarbonate glazed cabin with large windows, for total safety and optimum visibility of the work area.
* Internal cabinet for storing frequently used tools and materials (lenses, tips, kits for cleaning and centring optics, handbooks, etc) reduces machine maintenance and down time.
Even the most basic Syncrono model has all the technological solutions developed through Prima Industrie's long experience of laser machine technology; enabling extremely short cycle times and excellent cutting quality to be achieved as a matter of routine.
They include the following.
* Laser piercing monitor.
* Advanced restart functions.
* High-speed cutting with plasma formation.
* Automatic management of technological parameters for small and complex profiles.
* Microjoints.
* High-pressure cutting for high cutting speed and oxidation-free edges.
* Automatic detection of the metal sheet position for consequent adjustment of the program.
Programming Syncrono is extremely simple.
The primary and secondary axes are controlled fully automatically and 'transparently' for the user.
The Primach-20L CNC has an operator/machine interface with Web technology, Windows 2000 operating system, LCD flat screen, touch-screen and trackball; the 'Easy Cut' option enables fast programming directly on the machine.
Syncrono can be programmed off-line with PICAM, CAD-CAM 2D software for fast and simple generation of the complete machining program, based on mathematical models of the workpieces.
Parameter tables allow a choice of the best cutting parameters for every process.
Offering easy customisation to specific user requirements, these tables are always available in official versions of Prima's CNC and PICAM system.
Similarly, production times and costs can be further optimised by using the company's nesting and common line cutting modules.
What makes Syncrono unique?
* It is the fastest machine on the market (more than 6G acceleration during cutting), for consistently shorter cycle times, and corresponding production cost savings.
* Extreme speed and maximum cutting quality without compromise, i e, without the need to sacrifice one parameter to achieve the other.
* Uniform precision and cutting quality throughout the entire work area.
* Minimised operating costs through innovative machine design - with high dynamic minimum masses.
* Vibration-free for in-service precision and reliability over extended production runs.
Complementing Syncrono's capabilities is the following range of Prima productivity enhancing solutions.
* Automatic pallet changer; for minimum loading/unloading times - a virtually necessity for such a fast machine.
* PrimaServer range of automated material handling and storage systems.
The modular design of these systems allows installations to be upgraded at a later date, as production requirements increase, up to fully automated production units.
* PrimaServer Manager for controlling unmanned production.
* Remote sensing and safety cut out - with automatic reporting on the status of the machine via CNC.
Using the above options, it is possible to tailor installations precisely to customer production needs, right up to fully automatic, 'lights-out' operations.
With PrimaServer, a number of unmanned production options are available.
TowerServer (customisable with additional towers and rack feeder).
Automatic stacker/de-stacker for handling blank and processed sheets.
Tower unit with up to 15 storeys.
Elevator for loading and unloading work pallets on and off the tower.
Single sheet separation, measuring systems and sheet reference.
Unmanned production.
* Or CompactServer (extremely compact overall dimensions).
Automatic stacker/de-stacker for handling blank and processed sheets.
Twin-storey units (one for the blank sheets and one for the processed sheets).
Single sheet separation, measuring systems and sheet reference.
Controlled directly by the Syncrono CNC.
* The company's LaserServer with PrimaSorting systems enable stand-alone automatic manufacturing cells to be created.
LaserServer for automatic loading/unloading of sheets.
Three stations for loading sheets, unloading the 'skeletons' and unloading finished parts.
Sorting gripper for picking up and stacking finished parts.
Automatic programming of sorting cycles.
Other solutions, integrated to specific customer requirements, are available as multi-tower and multi-machines.
Multi-tower systems enable plant production capacity to be increased in stages.
They operate in conjunction with the automatic pallet changer - the interface point of with the machine - and provide virtually limitless configuration possibilities.
Multi-machine solutions link several machines simultaneously.
At their heart is The PrimaServer Manager system, which controls unmanned production and ensures both simplicity and efficiency - even in complex installations with several machines operating in extended workshop areas.
Syncrono's unparalleled capabilities can be demonstrated by simple analysis of the cycle times it achieves.
The following examples provide direct comparisons with machines that were regarded as benchmark laser cutters prior to the Syncrono's launch.
The first shows Syncrono's ability to cut a matrix of holes in light gauge sheet metal (1mm carbon steel).
The machine produces 1034 holes/min, against a 'benchmark' of 600 holes/min.
The second example represents the complete production cycle of a test workpiece including contouring, plus the production of a series of holes and slots with various shapes.
Using linear motors machines, the benchmark cycle time was 22s for the production of this component in 1mm thick carbon steel.
By comparison, the Syncrono completed the component in just 13.4s.
These cycle times demonstrate how Prima's new machine represents an effective answer to the market's ongoing demands for enhanced productivity.

CNC punch press choice based on experience

2006-12-16T01:26:00.001-08:00

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

2006-12-16T01:25:00.000-08:00

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.

Debris shields reduce high power laser costs

2006-12-15T01:25:00.000-08:00

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

2006-12-15T01:24:00.000-08:00

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.

Disc lasers cut glass with zero kerf width

2006-12-14T01:24:00.000-08:00

Device pre-drills before waterjet cutting

2006-12-14T01:23:00.000-08:00

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

2006-12-13T01:22:00.001-08:00

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

2006-12-13T01:22:00.000-08:00

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.

Waterjet, robotic systems, spindle technology

2006-12-12T01:21:00.000-08:00

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

2006-12-12T01:20:00.000-08:00

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'.

Nitrogen generator reduces laser cutting cost

2006-12-11T01:29:00.001-08:00

Laser machinist acquires precision parts maker

2006-12-11T01:25:00.001-08:00

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.

Device pre-drills before waterjet cutting

2006-12-10T01:28:00.000-08:00