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.

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.

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.

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.

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.

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.

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.

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.'

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 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.

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.

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.