ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.
The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.
The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.
High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.
Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.
Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.
Cutting and marking operations can be carried out with the same consumables.
The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.
Sunday, September 13, 2009
Friday, August 28, 2009
Walter solid carbide cutters machine titanium
The Prototyp Protostar Ti45 and Ti40 shank-style solid carbide milling cutters from Walter GB provide a universal solution for roughing and finishing cycles.
The Protostar Ti45 has a helix angle of 45 degrees and a cutting-edge length-to-diameter ratio of 5:1.
This configuration makes it ideal for high-speed finishing applications on demanding cycles such as those involving high webs and extended walls within a component.
The cutter is available in 16, 20 and 25mm diameters and with a choice of 3mm or 4mm radii.
Each cutter has a specially developed micro geometry on the periphery of the cutting edge, which enables high orders of surface finish and blend to be created.
Low vibration under cut is a major advantage obtained from the unequal edge-spacing of the Protostar Ti40 end mill when used for rough and finish milling.
As with the Ti45, the specially developed micro geometry on the periphery of the cutting edge creates an enhanced surface finish.
Through pre-treatment of the tool, built-up edge is prevented, which extends the reliability factor of any process and, through a post-coating treatment, which forms part of the ACN coating process, cutting-edge life is also increased.
Available in diameters between 12 and 25mm, the Prototyp Protostar Ti40 can also be specified with radii of 0.2, 2, 2.5, 3 and 4mm set at the transition point between the primary and secondary cutting edges.
Both tool types are also available in imperial sizes.
Milling cutters have wavy helix configuration
Cutwel has introduced solid carbide milling cutters from YG-1 for machining stainless steels, titanium alloys, inconel, tool steels, cast iron, mild steels and low hardness materials under HRc 40.
The cutter is made from a K30/K40 premium-grade carbide and a variable helix geometry has been manufactured into its flute form.
The V7 cutters have a wavy (sinusoidal) helix configuration and the index and helix on each portion of the cutting edge changes along the flute to give smooth cutting and chip removal.
This helps to reduce vibration and produce silent machining; improve surface finish due to the chatter-free design; increase cutting depths and give higher feed rates; and makes it possible to rough and finish with one cutter with minimised tool deflection and take a depth of cut equal to the cutter diameter.
It also features corner radius cutters for strength and protection against chipping and an Altin coating to reduce friction and dissipate any heat during cutting.
Application cutting area: stainless steel: 80-100m/min; titanium: 80-90m/min; inconel: 20-30m/min; alloy steels; and cast iron: 120-150m/min.
Seco releases PVD-coated MP3000 grade for steels
Seco Tools has brought out the MP3000 milling grade, which provides optimal performance in milling steel and tool steels with relatively thin average chip thickness.
The new grade is especially effective in square shoulder and copy milling applications where wear resistance and tool life need to be improved.
In these applications, MP3000 has shown a 40 per cent increase in tool life and up to a 200 per cent increase in machined components as compared with competitive steel machining grades.
The new MP3000 cemented carbide makes the grade hard and tough.
A slightly thicker PVD coating increases wear resistance over a large application range and an improved coating process increases coating adhesion, edge quality and edge integrity.
Although developed to enable higher speed capabilities in milling of steels, MP3000 is also suited for use as an optimising solution for machining of stainless steels and heat-resistant alloys.
The new grade is offered in a range of insert geometries to cover face, square shoulder and copy-milling applications.
It is especially effective when paired with Seco's new Square 6 milling cutter, serving as a first-choice tool for a variety of general machining operations.
Seco Tools is part of Seco Tools AB (Fagersta, Sweden), a world leader in metalworking technologies.
Horn to exhibit DAH milling cutters at EMO
Horn Cutting Tools will showcase its products at the forthcoming EMO 2009 in Milan, in partnership with Italian partner Febametal SpA.
The exhibits will include ground-in chipbreaker technology to maximise the performance of Supermini boring tools, as shown in the new HV geometry.
Among the all-new Horn products on show in Milan will be a range of milling cutters for high-feed milling applications and a range of high-precision reamers.
The new DAH milling cutters have been developed for requirements in tool making and mould making for roughing with high feed rates and low cutting depths.
The inserts ensure optimum distribution of the cutting forces as they act to transfer cutting forces in an axial direction and thereby reduce the spindle load.
Depending on the material, feed rates up to 3mm/tooth can be achieved for a maximum cutting depth of 1.2mm.
The triple-edged inserts are available in carbide-grade SA4B, which offers high wear resistance for milling steel and cast materials.
The titanium nitride (TiN) coated holders have through-coolant capability and are available as end mills with Weldon toolholder and as industry-standard threaded connection cutters with the MD holder design already tried and tested in the DA system.
The new DAH milling system features cutting-edge diameters of 20, 25, 32 and 40mm.
Existing Horn milling systems for 0.2 to 32mm diameter comprise the solid-carbide DS milling cutters, the DM combined milling cutters and the DA round-shank and industry-standard threaded connection milling cutters with triple-edged indexable insert.
Horn is also introducing the DR Reaming range of precise reamers.
The range is being produced under licence from the Swiss company Urma AG in Rupperswil and comprises of cutters, inserts, adapters and alignment aids.
A major feature of the DR reamers is the narrow, patented cutters for precision machining of steels, cast materials, non-ferrous metals and plastics.
They are available with cutting-edge diameters from 11.9 to 100.6mm in coated carbide, non-coated carbide and cermet versions.
All diameters are available with IKD straight-tooth geometry for reaming through-holes and IKS left helical rising-tooth geometry for reaming blind-hole drillings.
Depending on the material to be machined, four cutting geometries for the straight-tooth versions and two for the helical rising-tooth variants can be selected.
A positioning pin and screws with specified torques on the face side allow the cutter to be quickly changed.
Adjustable chucks simplify checking and adjustment of concentricity.
The cutter holders are available as cylindrical shank with internal coolant supply in short and long versions with diameters from 11.9 to 35.6mm.
Shanks with diameters from 35.6 to 100.6mm have their own alignment mechanism.
Cutwel unveils YG-1 solid carbide milling cutter
Cutwel has introduced an advanced solid carbide milling cutter from YG-1 for machining hardened steels, stainless steels, alloy and non-alloy steels, cast iron and heat-resistant steels up to HRc 70.
This new-generation X-Power cutter is made from a fine micrograin premium-grade carbide, which is processed in high-temperature furnaces.
These furnaces enable the carbide to be manufactured with a consistent carbide grain structure with no porosity.
After cooling down, the carbide is said to be very tough.
The hard PVD coating on the X-Power carbide cutting tools was developed for its good thermal and chemical stability, making it suitable for high-speed machining on high-hardness materials under extreme cutting conditions, making these cutters ideal for dry cutting.
It is recommended for tool making, mould and die, aerospace and the automotive industry.
The coating helps to protect the tools against premature wear and is suitable for running lights out or on long cutting cycle times.
This enables fast chip removal.
Cutter sizes range from 0.4mm to 25mm in diameter.
Ball nose cutters are ideal for machining difficult-to-cut complex 3D forms.
Corner radius cutters provide strength and protection against chipping.
Six- and eight-flute 45-degree helix cutters are available in long and extra-long sizes.
Miniature cutters are available for machining small complex features.
Two- and four-flute cutters are offered for slotting and side cutting.
Dry cutting is claimed to reduce the need for expensive coolants and productivity is maximised with increased speeds and feeds.
A long tool life is said to be guaranteed thanks to the X-Power coating, which protects against premature wear.
All cutters provide excellent component surface finish, according to the company.
Faster cycle times also lead to cost savings.
Full technical back-up is offered on cutter selection, speed feeds and recommended depths of cut.
Kennametal unveils shrink-fit toolholding system
As part of its complete tooling solution from the spindle face to the cutting edge, Kennametal has announced its shrink-fit toolholding system for machining centres and multi-tasking machines.
The shrink-fit system is split in two lines.
With the GP (general purpose) line, carbide, HSS and steel shanks can be accommodated with clamping torques suitable for most general engineering, die and mould, automotive and other machining tasks.
For heavy roughing operations requiring a higher clamping torque level, or for machining difficult-to-cut materials such as those found in the aerospace industry, the HT (high torque) line is recommended.
The HT line has a 30 per cent to 50 per cent higher clamping torque compared to the GP line.
The results are improved chip removal, faster performance and increased productivity for the end user.
For tolerancing hollow-shank (HSK) toolholders, taper is much tighter than that of any conventional 7/24 taper shanks.
For example, with a HSK63A, the taper tolerance is around several microns.
'Due to the trend toward higher cutting speeds, all the latest HSK shrink-fit toolholders have a balancing quality of G2.5 at 25,000rpm,' said product manager Oliver Moeller.
The Kennametal shrink-fit programme also accommodates steep taper, BT, CV and DV back ends.
According to Kennametal, the key features are: a very rigid and accurate connection to the tool holder; a shrinking and cooling process that will not last more than 30 seconds; very precise concentricity (3um); major process advantages in milling operations; slim profile for chucks for milling deep cavities; through-hole for coolant; and axial adjustment/backstop; and accommodates roughing, semi-finishing and finishing operations.
WNT extends Ultramini grooving tool range
WNT's range of Ultramini solid carbide grooving tools has been extended with axial and radial grooving tools and the addition of a high-pressure through-coolant facility.
The range of axial (face) grooving tools benefits from two integral coolant holes capable of accepting coolant pressure up to 100 bar.
Face grooves down to 3mm wide, at diameters over 16mm, can be cut up to 40mm deep, as the high-pressure coolant ensures that swarf is efficiently and reliably evacuated from the groove.
Axial grooving tools without through coolant are available down to 1mm in width.
the axial grooving range also uses a K10F TiAlN-coated carbide that has been developed with this type of application in mind.
A two-micron thick coating helps to achieve a sharp cutting edge geometry to reduce vibrating and minimise chatter, while extending the life of the cutting edge.
The Ultramini radial grooving tools can be also specified with through-tool coolant.
Available in groove widths from 1.0 to 3.0mm to cut grooves up to 30mm inside a bore, the tools also make use of the K10F TiAlN-coated carbide.
Both axial and radial tools are held in a steel body that features a fixed backstop, with the accuracy of the cutting tool being such that they repeat within microns, allowing tool changes to be completed quickly, with no need to alter the backstop or tool offset.
Friday, August 21, 2009
ESAB launches CNC plasma-arc cutting power source
ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.
The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.
The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.
High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.
Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.
Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.
Cutting and marking operations can be carried out with the same consumables.
The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.
The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.
The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.
High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.
Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.
Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.
Cutting and marking operations can be carried out with the same consumables.
The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.
ESAB introduces Falcon cutting machine
The Falcon entry-level compact cutting machine from ESAB Cutting Systems can be fitted with oxy-fuel cutting torches or can be supplied as an oxy-fuel package prepared for plasma-arc cutting.
Small engineering businesses can use this capability to produce quality steel construction and cut components in-house rather than using a subcontractor.
With its integrated CNC system, Falcon offers a fast, flexible, automated cutting solution capable of producing cut components on demand.
It is a suitable choice for workshops where space is at a premium and is designed to cut plate sizes up to a maximum of 2m x 6m with positioning speeds of up to 9m/min.
The Falcon has the option of being upgraded at a later date to a different process for specific cutting tasks.
Depending on the cutting process selected, it can cut steel, aluminium and alloyed steel up to 100mm thick.
The CNC system contains a cutting database with 65 programs for reproducible quality and high productivity.
Other features include two installed workpiece carriers with quick-release connections for easy positioning, plus a transverse and linear drive system with three-phase current for high cutting accuracies over the entire cutting range.
Copies of the latest Falcon literature are now available from ESAB Cutting Systems.
Small engineering businesses can use this capability to produce quality steel construction and cut components in-house rather than using a subcontractor.
With its integrated CNC system, Falcon offers a fast, flexible, automated cutting solution capable of producing cut components on demand.
It is a suitable choice for workshops where space is at a premium and is designed to cut plate sizes up to a maximum of 2m x 6m with positioning speeds of up to 9m/min.
The Falcon has the option of being upgraded at a later date to a different process for specific cutting tasks.
Depending on the cutting process selected, it can cut steel, aluminium and alloyed steel up to 100mm thick.
The CNC system contains a cutting database with 65 programs for reproducible quality and high productivity.
Other features include two installed workpiece carriers with quick-release connections for easy positioning, plus a transverse and linear drive system with three-phase current for high cutting accuracies over the entire cutting range.
Copies of the latest Falcon literature are now available from ESAB Cutting Systems.
Autodrill adds option to cutting machines
Autodrill has enabled a manufacturer of oxyacetylene cutting machines to offer a hole drilling option.
Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.
By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.
The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.
Annular cutters with a positive plug ejection system can also be used for some applications.
All the equipment is rated for continuous duty production work.
Autodrill offers free application and design assistance during the quote and post-sale process.
Free CAD drawings are available for all equipment.
A search for Autodrill on Youtube and other video sites turns up a number of example videos.
Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.
By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.
The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.
Annular cutters with a positive plug ejection system can also be used for some applications.
All the equipment is rated for continuous duty production work.
Autodrill offers free application and design assistance during the quote and post-sale process.
Free CAD drawings are available for all equipment.
A search for Autodrill on Youtube and other video sites turns up a number of example videos.
ESAB PDM tracks cutting system performance
ESAB Cutting Systems production data management system (PDM) is designed to control, track, record and report the performance of a cutting system in real time.
It allows data related to cutting and marking process to be captured and interfaced with existing business-planning systems.
By making production performance transparent, operational costs can be lowered and cycle times can be reduced.
The PDM system has a number of different modules that can be added as required.
These modules include PDM Workshop View, which provides automatically updated visualisation of all cutting machines connected to the PDM system.
It gives a detailed view of current and historical machine processes and performance.
The PDM Maintenance module records wear and usage of consumables while the PDM Event Control database records machine downtime and error messages.
When combined, the various modules give fully automated machine data logging and can plan detailed working orders for each cutting machine to maximise productivity.
It allows data related to cutting and marking process to be captured and interfaced with existing business-planning systems.
By making production performance transparent, operational costs can be lowered and cycle times can be reduced.
The PDM system has a number of different modules that can be added as required.
These modules include PDM Workshop View, which provides automatically updated visualisation of all cutting machines connected to the PDM system.
It gives a detailed view of current and historical machine processes and performance.
The PDM Maintenance module records wear and usage of consumables while the PDM Event Control database records machine downtime and error messages.
When combined, the various modules give fully automated machine data logging and can plan detailed working orders for each cutting machine to maximise productivity.
PP Plasma uses ESAB submerged plasma cutter
PP Plasma, a specialist in plasma, laser and waterjet profiling, has invested in an ESAB Cutting Systems Suprarex SXE P2 submerged plasma cutting machine for its purpose-built premises in Salford.
It has replaced two existing plasma machines and has given the company the capacity to deal with the demand for its products and services from many industries, including aerospace.
PP Plasma cuts stainless steel, aluminium and titanium in material thicknesses from 1mm to 150mm.
The Suprarex SXE P2 is predominantly used for stainless-steel grades in thicknesses ranging from 26mm to 100mm.
It is an underwater plasma profiling machine and this provides PP Plasma with environmental benefits, helping it to comply with legislation, since noise, fumes and glare are eliminated by cutting underwater.
The machine is equipped with the ESP 600 plasma 750A power source, which is regulated automatically depending on the thickness and the type of the metal to be cut.
A Vision 52 CNC control system has also been supplied - this automatically controls all the plasma cutting functions from its database to ensure optimum cutting quality without operator intervention.
Changeover and setup times between different thickness changes are kept to a minimum.
Gas selection and pressures are also changed automatically to ensure the best quality of cut.
It has replaced two existing plasma machines and has given the company the capacity to deal with the demand for its products and services from many industries, including aerospace.
PP Plasma cuts stainless steel, aluminium and titanium in material thicknesses from 1mm to 150mm.
The Suprarex SXE P2 is predominantly used for stainless-steel grades in thicknesses ranging from 26mm to 100mm.
It is an underwater plasma profiling machine and this provides PP Plasma with environmental benefits, helping it to comply with legislation, since noise, fumes and glare are eliminated by cutting underwater.
The machine is equipped with the ESP 600 plasma 750A power source, which is regulated automatically depending on the thickness and the type of the metal to be cut.
A Vision 52 CNC control system has also been supplied - this automatically controls all the plasma cutting functions from its database to ensure optimum cutting quality without operator intervention.
Changeover and setup times between different thickness changes are kept to a minimum.
Gas selection and pressures are also changed automatically to ensure the best quality of cut.
NUM to exhibit tool head and 3D simulation package
NUM will launch a ready-integrated tool head for sophisticated plasma-arc, laser and waterjet cutting machinery applications at EMO 2009, which is scheduled to take place in Milan on 5-10 October.
The CNC controls vendor also plans to exhibit an advanced 3D simulation package combining workpiece simulation with collision monitoring.
A novel mechanical design means that the new tool head provides the versatility of movement and stiffness required to implement a precision cutting motion, but with the advantages of very low mass and the elimination of cabling runs that must flex with the tool head movement and that can cause failures.
As a result of its light weight, the head can be assembled on existing CNC machines in the plasma- and waterjet-cutting market, often without additional mechanical adaptation, providing a simple means of extending the capability of machinery from 2D to 3D applications, with precise multi-axis interpolation.
NUM's 3D simulation package, meanwhile, combines workpiece simulation with collision monitoring and other powerful features.
The computer-aided-engineering (CAE) software allows machine builders to offer new generations of optimisation tools with their machines to help users maximise manufacturing throughput and productivity.
Designated True 3D, the software tool is a general-purpose version of NUM's 3D simulator for multi-axis grinding applications.
The new software is not only emulating but is simulating the actual CNC commands, hence the name True 3D, and subsequently provides an output as close as possible to the actual machined parts.
It allows machinery users to virtually prototype and optimise the entire machine production process to yield significant gains, including improved machine productivity, reduced tool wear and faster project completion.
The CNC controls vendor also plans to exhibit an advanced 3D simulation package combining workpiece simulation with collision monitoring.
A novel mechanical design means that the new tool head provides the versatility of movement and stiffness required to implement a precision cutting motion, but with the advantages of very low mass and the elimination of cabling runs that must flex with the tool head movement and that can cause failures.
As a result of its light weight, the head can be assembled on existing CNC machines in the plasma- and waterjet-cutting market, often without additional mechanical adaptation, providing a simple means of extending the capability of machinery from 2D to 3D applications, with precise multi-axis interpolation.
NUM's 3D simulation package, meanwhile, combines workpiece simulation with collision monitoring and other powerful features.
The computer-aided-engineering (CAE) software allows machine builders to offer new generations of optimisation tools with their machines to help users maximise manufacturing throughput and productivity.
Designated True 3D, the software tool is a general-purpose version of NUM's 3D simulator for multi-axis grinding applications.
The new software is not only emulating but is simulating the actual CNC commands, hence the name True 3D, and subsequently provides an output as close as possible to the actual machined parts.
It allows machinery users to virtually prototype and optimise the entire machine production process to yield significant gains, including improved machine productivity, reduced tool wear and faster project completion.
M3 plasma cutting system offers quick installation
ESAB Cutting Systems' M3 plasma cutting system is a complete high-performance system that is quick and easy to install and demands little in terms of operation and maintenance.
It offers a range of functions including marking and labelling and new cutting torch features have widened the scope of applications and improved cutting quality.
The latest PT-36 plasma-arc torch can replace up to three single-purpose torches and consumes fewer wear parts.
It enables the M3 plasma to carry out the high-quality precision cutting and marking of thick plate.
The torch can handle cuts of a variety of geometrical shapes, bevel cutting with a weld bevel angle of zero degrees to +/-45 degrees and the most common marking and labelling tasks.
The cutting thickness depends on the M3 plasma power source used and ranges between two and a maximum of 60mm in constructional steel, stainless steel and aluminium.
As an option, the PT-36 plasma-arc torch can now be upgraded for cuts up to 150mm in stainless steel and aluminium.
The M3 plasma system also uses ESAB's so-called shield gas technology, in which a secondary gas, such as oxygen or nitrogen, is used alongside the plasma gas, circulating around the arc and providing it with a protective, stabilising shell.
The result is a fine, accurate arc that has greater density and stability in comparison to conventional processes, according to the company.
This leads to higher cutting speeds, more precise cut edges and high-quality cut surfaces.
Small to medium-sized sub-contracting and manufacturing companies are said to be benefiting from the advantages of plasma-arc cutting thanks to falling costs and continually improving technology.
It offers a range of functions including marking and labelling and new cutting torch features have widened the scope of applications and improved cutting quality.
The latest PT-36 plasma-arc torch can replace up to three single-purpose torches and consumes fewer wear parts.
It enables the M3 plasma to carry out the high-quality precision cutting and marking of thick plate.
The torch can handle cuts of a variety of geometrical shapes, bevel cutting with a weld bevel angle of zero degrees to +/-45 degrees and the most common marking and labelling tasks.
The cutting thickness depends on the M3 plasma power source used and ranges between two and a maximum of 60mm in constructional steel, stainless steel and aluminium.
As an option, the PT-36 plasma-arc torch can now be upgraded for cuts up to 150mm in stainless steel and aluminium.
The M3 plasma system also uses ESAB's so-called shield gas technology, in which a secondary gas, such as oxygen or nitrogen, is used alongside the plasma gas, circulating around the arc and providing it with a protective, stabilising shell.
The result is a fine, accurate arc that has greater density and stability in comparison to conventional processes, according to the company.
This leads to higher cutting speeds, more precise cut edges and high-quality cut surfaces.
Small to medium-sized sub-contracting and manufacturing companies are said to be benefiting from the advantages of plasma-arc cutting thanks to falling costs and continually improving technology.
Brown McFarlane buys ESAB plasma power sources
Brown McFarlane of Stoke-on-Trent, a distributor and processor of steel plates, has invested in plasma power sources from ESAB Cutting Systems.
These are retrofitted to an ESAB Suprarex machine, which was originally acquired in 1995.
Brown McFarlane, which has a large ex-stock range of carbon and stainless plates, serves a variety of markets including process engineering, mining and the nuclear- and renewable-energy sectors.
The latest installation demonstrates how the incorporation of modern plasma-arc power sources into existing profiling technology can provide major benefits.
The Suprarex is regarded as the mainstay of Brown McFarlane's carbon steel profiling operations.
It is one of a number of plasma-arc profiling machines operated by the company for cutting both mild and stainless steel.
Brown McFarlane has invested in planned preventative maintenance and the upgrading of key components on a regular basis to enhance performance and ensure reliable operation.
This has included the renewal of the machine's rack and pinion drives and a new Vision 52 NC controller.
Now, two new 400A plasma-arc power sources have been added, replacing existing 200A sources, bringing extra power and higher cutting speeds as well as producing high-quality cuts that are dross free and with a minimal heat-affected zone.
The retrofitting of the two plasma units took three weeks at the Brown McFarlane plant at the start of 2009.
The Suprarex was completely stripped down and effectively rebuilt from scratch.
It is being used to pierce and cut mild steel from a thickness of 0.5mm to 50mm, up to 100mm from the material's edge.
The Vision 52 controller, with its LCD monitor and ergonomic keyboard, is said to be simple to use.
Its fully integrated database allows Brown McFarlane to set up fully automated production cycles that require no extra manual settings or operator intervention.
The optimum cutting parameters and speeds are set automatically for materials and thicknesses to be cut with and all cutting processes are controlled by the Vision 52.
In this way, Brown McFarlane is assured of both maximum productivity and maximum quality.
These are retrofitted to an ESAB Suprarex machine, which was originally acquired in 1995.
Brown McFarlane, which has a large ex-stock range of carbon and stainless plates, serves a variety of markets including process engineering, mining and the nuclear- and renewable-energy sectors.
The latest installation demonstrates how the incorporation of modern plasma-arc power sources into existing profiling technology can provide major benefits.
The Suprarex is regarded as the mainstay of Brown McFarlane's carbon steel profiling operations.
It is one of a number of plasma-arc profiling machines operated by the company for cutting both mild and stainless steel.
Brown McFarlane has invested in planned preventative maintenance and the upgrading of key components on a regular basis to enhance performance and ensure reliable operation.
This has included the renewal of the machine's rack and pinion drives and a new Vision 52 NC controller.
Now, two new 400A plasma-arc power sources have been added, replacing existing 200A sources, bringing extra power and higher cutting speeds as well as producing high-quality cuts that are dross free and with a minimal heat-affected zone.
The retrofitting of the two plasma units took three weeks at the Brown McFarlane plant at the start of 2009.
The Suprarex was completely stripped down and effectively rebuilt from scratch.
It is being used to pierce and cut mild steel from a thickness of 0.5mm to 50mm, up to 100mm from the material's edge.
The Vision 52 controller, with its LCD monitor and ergonomic keyboard, is said to be simple to use.
Its fully integrated database allows Brown McFarlane to set up fully automated production cycles that require no extra manual settings or operator intervention.
The optimum cutting parameters and speeds are set automatically for materials and thicknesses to be cut with and all cutting processes are controlled by the Vision 52.
In this way, Brown McFarlane is assured of both maximum productivity and maximum quality.
Tuesday, August 18, 2009
Autodrill adds option to cutting machines
Autodrill has enabled a manufacturer of oxyacetylene cutting machines to offer a hole drilling option.
Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.
By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.
The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.
Annular cutters with a positive plug ejection system can also be used for some applications.
All the equipment is rated for continuous duty production work.
Autodrill offers free application and design assistance during the quote and post-sale process.
Free CAD drawings are available for all equipment.
A search for Autodrill on Youtube and other video sites turns up a number of example videos.
Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.
By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.
The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.
Annular cutters with a positive plug ejection system can also be used for some applications.
All the equipment is rated for continuous duty production work.
Autodrill offers free application and design assistance during the quote and post-sale process.
Free CAD drawings are available for all equipment.
A search for Autodrill on Youtube and other video sites turns up a number of example videos.
ESAB PDM tracks cutting system performance
ESAB Cutting Systems production data management system (PDM) is designed to control, track, record and report the performance of a cutting system in real time.
It allows data related to cutting and marking process to be captured and interfaced with existing business-planning systems.
By making production performance transparent, operational costs can be lowered and cycle times can be reduced.
The PDM system has a number of different modules that can be added as required.
These modules include PDM Workshop View, which provides automatically updated visualisation of all cutting machines connected to the PDM system.
It gives a detailed view of current and historical machine processes and performance.
The PDM Maintenance module records wear and usage of consumables while the PDM Event Control database records machine downtime and error messages.
When combined, the various modules give fully automated machine data logging and can plan detailed working orders for each cutting machine to maximise productivity.
It allows data related to cutting and marking process to be captured and interfaced with existing business-planning systems.
By making production performance transparent, operational costs can be lowered and cycle times can be reduced.
The PDM system has a number of different modules that can be added as required.
These modules include PDM Workshop View, which provides automatically updated visualisation of all cutting machines connected to the PDM system.
It gives a detailed view of current and historical machine processes and performance.
The PDM Maintenance module records wear and usage of consumables while the PDM Event Control database records machine downtime and error messages.
When combined, the various modules give fully automated machine data logging and can plan detailed working orders for each cutting machine to maximise productivity.
Brown McFarlane buys ESAB plasma power sources
Brown McFarlane of Stoke-on-Trent, a distributor and processor of steel plates, has invested in plasma power sources from ESAB Cutting Systems.
These are retrofitted to an ESAB Suprarex machine, which was originally acquired in 1995.
Brown McFarlane, which has a large ex-stock range of carbon and stainless plates, serves a variety of markets including process engineering, mining and the nuclear- and renewable-energy sectors.
The latest installation demonstrates how the incorporation of modern plasma-arc power sources into existing profiling technology can provide major benefits.
The Suprarex is regarded as the mainstay of Brown McFarlane's carbon steel profiling operations.
It is one of a number of plasma-arc profiling machines operated by the company for cutting both mild and stainless steel.
Brown McFarlane has invested in planned preventative maintenance and the upgrading of key components on a regular basis to enhance performance and ensure reliable operation.
This has included the renewal of the machine's rack and pinion drives and a new Vision 52 NC controller.
Now, two new 400A plasma-arc power sources have been added, replacing existing 200A sources, bringing extra power and higher cutting speeds as well as producing high-quality cuts that are dross free and with a minimal heat-affected zone.
The retrofitting of the two plasma units took three weeks at the Brown McFarlane plant at the start of 2009.
The Suprarex was completely stripped down and effectively rebuilt from scratch.
It is being used to pierce and cut mild steel from a thickness of 0.5mm to 50mm, up to 100mm from the material's edge.
The Vision 52 controller, with its LCD monitor and ergonomic keyboard, is said to be simple to use.
Its fully integrated database allows Brown McFarlane to set up fully automated production cycles that require no extra manual settings or operator intervention.
The optimum cutting parameters and speeds are set automatically for materials and thicknesses to be cut with and all cutting processes are controlled by the Vision 52.
In this way, Brown McFarlane is assured of both maximum productivity and maximum quality.
These are retrofitted to an ESAB Suprarex machine, which was originally acquired in 1995.
Brown McFarlane, which has a large ex-stock range of carbon and stainless plates, serves a variety of markets including process engineering, mining and the nuclear- and renewable-energy sectors.
The latest installation demonstrates how the incorporation of modern plasma-arc power sources into existing profiling technology can provide major benefits.
The Suprarex is regarded as the mainstay of Brown McFarlane's carbon steel profiling operations.
It is one of a number of plasma-arc profiling machines operated by the company for cutting both mild and stainless steel.
Brown McFarlane has invested in planned preventative maintenance and the upgrading of key components on a regular basis to enhance performance and ensure reliable operation.
This has included the renewal of the machine's rack and pinion drives and a new Vision 52 NC controller.
Now, two new 400A plasma-arc power sources have been added, replacing existing 200A sources, bringing extra power and higher cutting speeds as well as producing high-quality cuts that are dross free and with a minimal heat-affected zone.
The retrofitting of the two plasma units took three weeks at the Brown McFarlane plant at the start of 2009.
The Suprarex was completely stripped down and effectively rebuilt from scratch.
It is being used to pierce and cut mild steel from a thickness of 0.5mm to 50mm, up to 100mm from the material's edge.
The Vision 52 controller, with its LCD monitor and ergonomic keyboard, is said to be simple to use.
Its fully integrated database allows Brown McFarlane to set up fully automated production cycles that require no extra manual settings or operator intervention.
The optimum cutting parameters and speeds are set automatically for materials and thicknesses to be cut with and all cutting processes are controlled by the Vision 52.
In this way, Brown McFarlane is assured of both maximum productivity and maximum quality.
Plasma-arc developments on display in Essen
Kjellberg Finsterwalde will demonstrate plasma-arc developments for welding and plasma cutting at the Schweissen and Schneiden 2009 trade fair in Essen, Germany.
Among the demonstrations will be the plasma torch Percut 450M, which will be presented on a Hifocus 440i plasma cutting machine at the rotator of the guiding machine.
This torch is equipped with long-life consumables and can cut at extremely high speeds.
An Automatic Torch Changer (ATC) installed on the same guiding system will show how a flexible and quick automated change of torch heads can be carried out.
The Cuti manual plasma cutting machines are characterised by low weight and high capability.
The inverter Cuti 35C with integrated compressor allows cutting independently of an external compressed-air supply.
The new Cutfire 100i is a simple and reliable plasma cutting unit.
It is light and offers 100 per cent duty cycle, making it suitable for simple CNC applications.
The Cutfire 100i is especially suitable for cutting thin and medium-sized plates.
The new generation of YellowXlife consumables for plasma-cutting achieves up to 3.5-times longer lifetime.
These consumables improve labour productivity.
Kjellberg Finsterwalde is offering Newarc for most application-areas of MIG welding.
Newarc is more focussed than the spray arc.
Other advantages include higher welding speed, deep and stable root fusion, good welding-seam quality and reduced power-consumption.
Wear-protection systems offer hardness and corrosion resistance on extruder screws, flanges and, for example, rollers, by applying plasma powder deposition welding, which will be demonstrated at a separate welding stand.
Among the demonstrations will be the plasma torch Percut 450M, which will be presented on a Hifocus 440i plasma cutting machine at the rotator of the guiding machine.
This torch is equipped with long-life consumables and can cut at extremely high speeds.
An Automatic Torch Changer (ATC) installed on the same guiding system will show how a flexible and quick automated change of torch heads can be carried out.
The Cuti manual plasma cutting machines are characterised by low weight and high capability.
The inverter Cuti 35C with integrated compressor allows cutting independently of an external compressed-air supply.
The new Cutfire 100i is a simple and reliable plasma cutting unit.
It is light and offers 100 per cent duty cycle, making it suitable for simple CNC applications.
The Cutfire 100i is especially suitable for cutting thin and medium-sized plates.
The new generation of YellowXlife consumables for plasma-cutting achieves up to 3.5-times longer lifetime.
These consumables improve labour productivity.
Kjellberg Finsterwalde is offering Newarc for most application-areas of MIG welding.
Newarc is more focussed than the spray arc.
Other advantages include higher welding speed, deep and stable root fusion, good welding-seam quality and reduced power-consumption.
Wear-protection systems offer hardness and corrosion resistance on extruder screws, flanges and, for example, rollers, by applying plasma powder deposition welding, which will be demonstrated at a separate welding stand.
M3 plasma cutting system offers quick installation
ESAB Cutting Systems' M3 plasma cutting system is a complete high-performance system that is quick and easy to install and demands little in terms of operation and maintenance.
It offers a range of functions including marking and labelling and new cutting torch features have widened the scope of applications and improved cutting quality.
The latest PT-36 plasma-arc torch can replace up to three single-purpose torches and consumes fewer wear parts.
It enables the M3 plasma to carry out the high-quality precision cutting and marking of thick plate.
The torch can handle cuts of a variety of geometrical shapes, bevel cutting with a weld bevel angle of zero degrees to +/-45 degrees and the most common marking and labelling tasks.
The cutting thickness depends on the M3 plasma power source used and ranges between two and a maximum of 60mm in constructional steel, stainless steel and aluminium.
As an option, the PT-36 plasma-arc torch can now be upgraded for cuts up to 150mm in stainless steel and aluminium.
The M3 plasma system also uses ESAB's so-called shield gas technology, in which a secondary gas, such as oxygen or nitrogen, is used alongside the plasma gas, circulating around the arc and providing it with a protective, stabilising shell.
The result is a fine, accurate arc that has greater density and stability in comparison to conventional processes, according to the company.
This leads to higher cutting speeds, more precise cut edges and high-quality cut surfaces.
Small to medium-sized sub-contracting and manufacturing companies are said to be benefiting from the advantages of plasma-arc cutting thanks to falling costs and continually improving technology.
It offers a range of functions including marking and labelling and new cutting torch features have widened the scope of applications and improved cutting quality.
The latest PT-36 plasma-arc torch can replace up to three single-purpose torches and consumes fewer wear parts.
It enables the M3 plasma to carry out the high-quality precision cutting and marking of thick plate.
The torch can handle cuts of a variety of geometrical shapes, bevel cutting with a weld bevel angle of zero degrees to +/-45 degrees and the most common marking and labelling tasks.
The cutting thickness depends on the M3 plasma power source used and ranges between two and a maximum of 60mm in constructional steel, stainless steel and aluminium.
As an option, the PT-36 plasma-arc torch can now be upgraded for cuts up to 150mm in stainless steel and aluminium.
The M3 plasma system also uses ESAB's so-called shield gas technology, in which a secondary gas, such as oxygen or nitrogen, is used alongside the plasma gas, circulating around the arc and providing it with a protective, stabilising shell.
The result is a fine, accurate arc that has greater density and stability in comparison to conventional processes, according to the company.
This leads to higher cutting speeds, more precise cut edges and high-quality cut surfaces.
Small to medium-sized sub-contracting and manufacturing companies are said to be benefiting from the advantages of plasma-arc cutting thanks to falling costs and continually improving technology.
Wednesday, August 12, 2009
Nano-grain carbide endmills machine hard materials
The X5070, available from Cutwel, is a range of nano-grain-size upgraded premium carbide endmills specifically designed for machining hardened materials in a range of 50-70HRc.
The X5070 endmills were produced in order to fill the large gap between the 'normal' carbide and the premium, specifically for increasing tool life when machining the upper range of hardened materials.
They can also be used to substitute for many grinding operations.
The X5070 range is used in high-speed cutting (HSC), dry cutting, machining die and mould and tool steels.
The premium carbide endmills are harder than conventional carbide but have almost the same toughness.
They have a very fine nano-grain size and uniform carbide particles, providing better wear resistance, which prolongs tool life.
In addition, they have a superior hot hardness material heat barrier, which permits a higher cutting temperature and provides greater hot hardness at the tool/chip interface (most of the heat is carried away with the chips).
The X5070 range of endmills has optimum geometry and is designed with higher corner edge strength by a process that improves cutting corner smoothness.
As a result, there is improvement in workpiece surface roughness, straightness, perpendicularity and repeatability in performance.
The X5070 is covered with the company's specially developed coating for the upper range of hardened material, which combines high hardness (more than 3,600HV), high thermal stability against oxidation (900C) and low coefficient of friction against steel.
As a result, wear resistance is improved, prolonging tool life, with higher cutting speeds and feeds.
The X5070 is suitable for dry-cutting and clean-machining processes, reducing coolant costs.
WNT supplement expands cutting tool catalogue
WNT has announced that updates to its catalogue, which runs to more than 1,600 pages and containing around 45,000 products, have been consolidated into a 224-page supplement.
This supplement, which includes updates issued by WNT over the past 12 months, will be distributed to customers in the coming weeks.
The extensive metal cutting tool catalogue from WNT (UK) has over 1600 pages, which contain some 45 000 products.
It contains every update and new product that has been introduced since the main catalogue was launched in May 2008 and replaces all of the intervening product updates.
'With almost 10 per cent of the content of the main catalogue being replaced with upgraded or brand new cutting tools on an annual basis we publish many updates over the course of a year,' says Tony Pennington, managing director, WNT (UK).
'We are now bringing all of these changes together in a single publication.
'There will be a similar number of new products launched in the next 12 months and these will be incorporated into the new main catalogue when it is launched in 2010,' he added.
Cutting tool catalogue features end mills and more
ITC has launched the sixth issue of its cutting tool catalogue.
The edition incorporates recently launched tools, including the aluminium series of 2131 Cyber series two-flute extra-long series (XLS) end mills and the 2142 Cyber series two-flute ball-nosed XLS end mill.
For the machining of abrasive materials such as graphite, metal matrix and carbon fibre used in the aerospace, motorsport and mould and die sectors, the catalogue introduces the 2151 Cyber series of two-flute XLS PCD end mills and the 2132 series of solid-carbide shank XLS PCD ball-nosed end mills.
Complementing the PCD line in the catalogue is the 2071 series of two-flute diamond-coated end mills for machining graphite.
For general machining applications, the catalogue introduces the 4111 series for back-chamfering and countersinking - available coated and uncoated, plus the 2141 series of 90-degree solid-carbide end mills for milling, drilling, spotting and chamfering.
ITC also manufactures and distributes a multitude of cutting tools for specialist applications from its facility in Tamworth.
The edition incorporates recently launched tools, including the aluminium series of 2131 Cyber series two-flute extra-long series (XLS) end mills and the 2142 Cyber series two-flute ball-nosed XLS end mill.
For the machining of abrasive materials such as graphite, metal matrix and carbon fibre used in the aerospace, motorsport and mould and die sectors, the catalogue introduces the 2151 Cyber series of two-flute XLS PCD end mills and the 2132 series of solid-carbide shank XLS PCD ball-nosed end mills.
Complementing the PCD line in the catalogue is the 2071 series of two-flute diamond-coated end mills for machining graphite.
For general machining applications, the catalogue introduces the 4111 series for back-chamfering and countersinking - available coated and uncoated, plus the 2141 series of 90-degree solid-carbide end mills for milling, drilling, spotting and chamfering.
ITC also manufactures and distributes a multitude of cutting tools for specialist applications from its facility in Tamworth.
Dormer announces rotary tooling products
Dormer has expanded the range of applications covered by its rotary tooling with the introduction of several products.
Highlights from the second of Dormer's biannual product launches include universal solid carbide end mills, cutters for steel and aluminium, and drills for deep hole applications.
The universal solid carbide cutters have been designed to offer high productivity and affordability across a wide range of materials and applications.
These are available in 2 flute (S922), 3 flute (S933) and 4 flute (S944) geometry with TiAlN coating.
Dormer's solid carbide cutters for steels include both medium (S250, S252) and long length (S254, S255) end mills designed for high metal removal operations, semi-roughing, semi-finishing and finishing.
All incorporate Dormer's unequal helix angle design that is said to provide greater stability, less tool vibration and a superior finish.
The solid carbide cutters for aluminium include the S143, S145 and S149, which feature extra-long effective length for contouring operations involving thin or high walls.
The S144 (with corner radius) can also be used for roughing, while the S540 (ball nosed) is suitable for 3D forming, profiling and several kinds of finishing operations.
HSCO drills for deep hole applications complete the programme.
Available in a variety of lengths - from stub to extra length - they cover drilling operations in most materials from 3xD (A920, A921), 6xD (A900, A901), 10xD (A940, A941) and 15xD (A976, A977, A978).
All product launches are supported by literature that includes full range details, dimensional data and optimum operating conditions.
Highlights from the second of Dormer's biannual product launches include universal solid carbide end mills, cutters for steel and aluminium, and drills for deep hole applications.
The universal solid carbide cutters have been designed to offer high productivity and affordability across a wide range of materials and applications.
These are available in 2 flute (S922), 3 flute (S933) and 4 flute (S944) geometry with TiAlN coating.
Dormer's solid carbide cutters for steels include both medium (S250, S252) and long length (S254, S255) end mills designed for high metal removal operations, semi-roughing, semi-finishing and finishing.
All incorporate Dormer's unequal helix angle design that is said to provide greater stability, less tool vibration and a superior finish.
The solid carbide cutters for aluminium include the S143, S145 and S149, which feature extra-long effective length for contouring operations involving thin or high walls.
The S144 (with corner radius) can also be used for roughing, while the S540 (ball nosed) is suitable for 3D forming, profiling and several kinds of finishing operations.
HSCO drills for deep hole applications complete the programme.
Available in a variety of lengths - from stub to extra length - they cover drilling operations in most materials from 3xD (A920, A921), 6xD (A900, A901), 10xD (A940, A941) and 15xD (A976, A977, A978).
All product launches are supported by literature that includes full range details, dimensional data and optimum operating conditions.
Walter solid carbide cutters machine titanium
The Prototyp Protostar Ti45 and Ti40 shank-style solid carbide milling cutters from Walter GB provide a universal solution for roughing and finishing cycles.
The Protostar Ti45 has a helix angle of 45 degrees and a cutting-edge length-to-diameter ratio of 5:1.
This configuration makes it ideal for high-speed finishing applications on demanding cycles such as those involving high webs and extended walls within a component.
The cutter is available in 16, 20 and 25mm diameters and with a choice of 3mm or 4mm radii.
Each cutter has a specially developed micro geometry on the periphery of the cutting edge, which enables high orders of surface finish and blend to be created.
Low vibration under cut is a major advantage obtained from the unequal edge-spacing of the Protostar Ti40 end mill when used for rough and finish milling.
As with the Ti45, the specially developed micro geometry on the periphery of the cutting edge creates an enhanced surface finish.
Through pre-treatment of the tool, built-up edge is prevented, which extends the reliability factor of any process and, through a post-coating treatment, which forms part of the ACN coating process, cutting-edge life is also increased.
Available in diameters between 12 and 25mm, the Prototyp Protostar Ti40 can also be specified with radii of 0.2, 2, 2.5, 3 and 4mm set at the transition point between the primary and secondary cutting edges.
Both tool types are also available in imperial sizes.
The Protostar Ti45 has a helix angle of 45 degrees and a cutting-edge length-to-diameter ratio of 5:1.
This configuration makes it ideal for high-speed finishing applications on demanding cycles such as those involving high webs and extended walls within a component.
The cutter is available in 16, 20 and 25mm diameters and with a choice of 3mm or 4mm radii.
Each cutter has a specially developed micro geometry on the periphery of the cutting edge, which enables high orders of surface finish and blend to be created.
Low vibration under cut is a major advantage obtained from the unequal edge-spacing of the Protostar Ti40 end mill when used for rough and finish milling.
As with the Ti45, the specially developed micro geometry on the periphery of the cutting edge creates an enhanced surface finish.
Through pre-treatment of the tool, built-up edge is prevented, which extends the reliability factor of any process and, through a post-coating treatment, which forms part of the ACN coating process, cutting-edge life is also increased.
Available in diameters between 12 and 25mm, the Prototyp Protostar Ti40 can also be specified with radii of 0.2, 2, 2.5, 3 and 4mm set at the transition point between the primary and secondary cutting edges.
Both tool types are also available in imperial sizes.
Tuesday, August 4, 2009
Advanced sliding head auto converts subby to OEM
Advanced CNC sliding head automatic lathe with two Y-axis cross feeds each to the turret and toolslide allowed a subcontractor to machine parts for its first original product.
John Harrison, the managing director of Microform Precision Engineering of Clayton West, just outside Huddersfield, UK, has achieved the goal of many subcontract (subby) machinists, that of successfully developing his own product.
Having purchased a Citizen C16 CNC sliding head auto in mid-2004 from NC Engineering of Watford, UK, he then decided three months later that a top of the range Series 3 Citizen M32 -V with two Y-axis cross feeds each to the turret and toolslide was what he needed to produce components for his patented electronic contact probe and tool touch sensor, as well as growing his business in production machining.
Microform Precision was originally set up by Harrison and his wife in 1977.
It bought its first CNC machine in 1989 and 10 years later moved into the current premises when they were first built.
The company has recently recruited works director James Vaughan who is mounting a charge to progress the business into a turned parts specialist where the newly installed Citizens play a key role to achieve a target of tripling the turnover with the same five employees who already run the firm through a seven day week 24h day regime.
And, already Vaughan has had his goals recognised with CNC sliding head autos contributing to the winning of one of two supplier credibility awards from a US customer, a certification that is highly sought after by its 120 suppliers.
The reason Harrison developed the probe and tool sensor was that he used proprietary probe systems on his machining centres and milling machines but maintains: "Like many users I was frequently damaging the stylus by running the probe into the job".
"I reckon that any electronic device fitted to a machine tool should be rugged enough to stand abuse".
"So I decided to develop my own which is considerably more competitively priced than others on the market." His probe and tool setting sensor has been designed for use on machine tools having an over travel of 6mm in each of the X, Y and Z axes.
It has a repeatability claim of better than five microns and has a robust shank 20mm long is able to access difficult areas using a 6mm diameter probe tip with flats rather than the traditional sphere.
Mill/turned parts will only now be produced on the two Citizen machines which will provide the extra capacity required for more difficult single cycle work to replace an existing four year old sliding head auto described by him as: "Not one of the best purchases I made." Vaughan supports the statement offering that the Citizens were immediately more impressive and as an example, the first job set up on the C16 did not require an offset adjustment for four days even while running around the clock".
""The machine it replaced would move 0.04 to 0.05mm every time the guard was opened," he says.
The C16 was the first Citizen machine in the UK to feature the oversize bar capacity of 18mm, "Just in case," says Vaughan, covering a capacity between 8mm and 18mm.
It also had the first duplex opposed head driven toolholder which enabled endworking at both the main and subspindles from a single tool position with cutters up to 8mm diameter.
It has a depth capability of up to 30mm in each direction.
The capacity of the M32 overlaps the C16 holding a bar size between 12mm and 32mm, it also has the 2000 lb/in2 CoolBlaster, high pressure coolant system, a programmable part retrieval system to clear working area and NC Engineering's Alarm Alert automatic call-out.
This is fitted to both machines should problems occur when running in lights out mode, and calls the duty operator on either mobile phone or land line giving details of the machine stoppage such as material shortage or process malfunction.
The tool capacity of up to 82 tools was important to Vaughan on the M32 because he is practising fast changeover techniques, leaving the machine set with common tools and grouping like materials and similar parts together.
He also maintains the machines were selected in order to provide a practical single cycle 'one-hit' solution to account for any feature, geometric tolerance or surface finish requirement set by the customer.
Already Microform Precision Engineering produces a wide range of parts in Delrin, plastics, aluminium, brass and stainless steels".
""You need flexibility and we have turned to a new chapter in our business to provide a finished part from the one machine".
"Previously, we had wasted hours on secondary operations and the associated problems," Vaughan maintains.
Vaughan and Harrison both firmly believe that delivery, quality and service are key: "You ca not ring the Far East and ask for panic order parts in two or three days, that is our delivery objective and we have now planned with the tooling set-up to be able to split, say a 5,000 batch, set-up for a few hundred parts against a special order and quickly switch back to the original CNC program and contract." That has meant a considerable spend on tooling to give flexibility but he confirms even deburring is simple on the Citizens: "You just program the interpolation required to take off a whisker around the profiles and the job is done, ready for washing," says Vaughan.
He is a great believer in the use of form tools and makes a lot of his own such as flat form tools step and combination drills.
This enables him to combine undercuts, grooves and diameters, chamfer and counterbores and combination drill cross holes.
Often one tool will do a whole series of parts which saves cycle time from tool indexing and having to perform multiple passes".
""It also helps when simultaneous cutting with a form tool when up to three tools are engaged at the same time enabling several features to be produced very quickly," he says.
The use of CoolBlaster follows the success of other Citizen M32 specifiers with tool life extended by at least 50% on 316 stainless steel, peck drilling eliminated and the benefit of much better swarf control.
Most important is the secondary collet cleaning between parts plus the bonus of cycle time improvement by up to 20%.
Among the jobs now falling under the single operation philosophy is a pin assembly for off-road vehicles.
This 75mm long 6mm diameter shaft with circlip grooves used to have to be ground to 15 micron tolerance with serrations produced in the centre for push fit assembly to a mating block.
Now the pin is made complete in one operation with a knurl in the centre which has been accepted by the customer.
Altogether, some 30s have been saved on production of the part.
A balancer shaft for a fuel injection system has been cut from two to one operation and a square flanged component with a spigot, central bore and four drilled and tapped pitch circle holes has shown a massive 70% saving on production times by combining four operations into one.
Cutting with three tools simultaneously the round bar is milled square, the centre bore drilled and bored and outside diameter of a spigot turned before a special ground subland drill is used to drill and countersink the four holes and interpolate around the part to provide a precision deburred edge.
But the classic is a medical industry connector made from 24mm diameter 316 stainless steel bar which has an offset eccentric bore that required a total of six operations to produce.
Previously production methods were made worse because tight process tolerances had to be applied to ensure fixturing would reproduce a blended milled form which then had to be finally polished by hand.
This part is now produced in one single cycle with all geometric relationships easily met, size and surface finish are now regarded as 'as machined', which eliminates all the additional handling, fixturing, inspection and polishing.
Metalcutting lubricants face auto materials change
Charsten Wienbreyer looks at the changing practice of automotive component manufacturing and how this is placing increased pressure on metalworking fluids.
Metalcutting lubricants face auto materials challenge Charsten Wienbreyer looks at the changing practice of automotive component manufacturing and how this is placing increased pressure on metalworking fluids.
The rising market demand for more economic vehicles, without compromise to performance and design, has presented automotive manufacturers with a particularly difficult Research and Development (R and D) challenge.
Following the agreement of the Kyoto protocol in 1997, many countries across the globe have taken action to reduce carbon dioxide emissions.
In Europe, this has seen a voluntary agreement among leading automotive manufacturers to produce higher fuel efficient and lower carbon emission producing vehicles.
To achieve this, while retaining and increasing the market appeal of their vehicles, many manufacturers are investing in new production techniques and technologies.
This R and D challenge has been intensified by the fact that a growing number of automotive manufacturers are capitalising on the skills and low costs of production now available in new, thriving automotive manufacturing industries.
Essentially, the boom of automotive manufacturing in places such as Eastern Europe and China has intensified competition by enabling companies to lower vehicle retail prices, while maintaining healthy profit margins.
* Changing production processes - one method that automotive manufacturers have utilised to improve overall vehicle efficiency is the production of lighter components.
Reducing the weight of components such as vehicle transmission, bodywork and gearboxes lowers the total weight of the finished vehicle and the demand placed on the engine during acceleration.
Therefore, lower total vehicle weight equals less fuel consumption during engine combustion, increasing fuel performance.
To make components lighter, manufacturers have switched from using basic steel compounds to various alloys and other light non-ferrous materials such as magnesium.
This switch provides a component of comparative durability to steel (in some cases durability can be increased), so that manufacturers do not have to alter vehicle design or performance.
Furthermore, vehicle safety can be improved as the new alloys offer greater resistance to failure during impact.
Using these alternative materials for component production can help reduce total vehicle weight by approximately 25%, offering manufacturers a cost effective way of significantly improving vehicle efficiency and environmental performance.
However, to reap the full financial benefits of this production solution, manufacturers need to ensure that their tools and metalworking fluids are able to cope with the pressures of machining tougher metals.
If not, they risk facing long periods of unscheduled stoppages and high levels of component and equipment damage.
One particularly successful method of protecting against these risks is by using a high performance, fit-for-purpose metalworking fluid.
* Fluid overview - metalworking fluids play an important role in the smooth and efficient running of automotive component manufacturing equipment as well as the successful formation of the finished part.
The extreme temperatures, high level of chipping and long continuous operational hours of metalworking processes, such as deep hole drilling, turning and broaching, place multiple demands on the fluid.
It must provide lubrication, flushing and cooling properties to protect the tool part from accelerated wear and the finished part from surface damage and deformation.
All metalworking processes generate intense heat as the metals or non-ferrous materials are processed.
However, the heat must be dissipated across the part surface and the friction must be reduced to avoid part damage and poor surface finish, which can be extremely costly for operators in terms of wastage and delays in production.
In the past, many fluids were formulated using chlorine as it provided excellent performance, even in low temperatures, protecting the tool and part against wear and damage.
Since the use of chlorine in fluids was banned approximately 10 - 15 years ago, fluids are now developed using different Extreme Pressure (EP) additives, meaning that fluids can be developed to meet specific operational requirements - providing operators with greater performance.
* Selecting the right fluid - increasing the strength of the metal that is being machined will lead to an increase in cutting duration, temperature and chipping.
As the majority of cutting fluids are developed to operate within certain temperature parameters, manufacturers must ensure that the fluid used is able to perform even with harsher demands of machining stronger metals.
There are generally four types of fluids used in metalworking: neat oils; soluble oils; semisynthetic and synthetic.
Selection of the fluid will depend on a number of variables specific to the cutting process and type of metal being machined.
These include the size of metal chips, cutting speed, duration and tolerance.
For example, a high wetting, anti-weld and anti-corrosion, water miscible metalworking fluid such as Shell Adrana A 2859 is required during deep hole drilling to flush chips from the cutting area and stop them from welding to the drill tool or part being drilled.
Whereas, a speciality product, such as Shell Sitala B 5801, with high resistance to water hardness and increases in pH levels is required to meet the challenges of machining magnesium alloys.
When it comes to metalworking fluids, there is no one size fits all and selecting the right fluid for the right application is key to protecting against tool failure or part damage.
If manufacturers are changing their production process to accommodate new, tougher metals or non-ferrous materials, they should always consider reviewing the performance properties of their metalworking fluid.
In many cases, an experienced metalworking fluids provider such as Shell Metalworking Lubricants will be able to assist automotive manufacturers in auditing the cutting process and identifying fluid demands.
This approach helps determine the required EP rating, wetting, cooling, anti-corrosion and flushing performance of the fluid.
* Driving down costs - the right metalworking fluid, supported with the relevant application expertise, will help automotive manufacturers protect their processes against expensive tool and component damage, while maintaining uptime.
In a market that continues to demand more value from the finished vehicle in terms of power, efficiency and environmental compliance - this could help manufacturers to ensure that their process remains productive and profitable.
* About the author - Charsten Wienbreyer is general manager of Shell MetalworkingAuto-parts suppliers should look outside
Beleaguered UK automotive component suppliers have been urged to look outside the car market for customers or face going bust as the European and US motor industry struggles.
Beleaguered automotive suppliers in the UK, hoping the sale of MG Rover will bring them new business, have been urged to look outside the car market for customers or face going bust themselves as the European and US motor industry struggles.
Global credit insurer Atradius says the collapse of MG Rover is the most recent of problems faced by automotive firms in Europe and the US.
In its latest Industry Risk Index, Atradius says that giant carmakers such as GM and Ford are seeing sales and profits fall as they attempt to cut costs, while equipment suppliers and component manufacturers are being undercut by imports from China and India.
In fact the only real bright spot in the current automotive market is the growing demand for accessories such as alloy wheels and in-car sound systems by 'boy-racers' souping up their suburban hatchbacks.
But rather than hoping that MG Rover's new Chinese owners, Nanjing, will restart production in the UK, Atradius says suppliers should explore other industry sectors for new business.
Will Clark, Atradius' regional director for UK and Ireland, NAFTA and Australasia, explains: "The interest shown in MG Rover by buyers from China reflects the growing presence in the automotive sector of developing countries.
The European and US dominance of the motor industry is coming to an end and suppliers need to wake up to this and develop new products for new customers in other industries." MG Rover went bust owing millions of pounds to suppliers across the UK.
But despite being bought by Nanjing for around GBP 60 million, Atradius says creditors will have to wait many months to see any money and are unlikely to be reimbursed in full.
Suppliers hardest hit by the collapse were those that had the car maker as their major customer and subsequently could not offset loses against other income streams.
Atradius had advised its credit insurance customers to reduce their exposure to MG Rover or spread their risk by finding other customers.
Consequently, when the company collapsed, Atradius' clients suffered fewer losses.
However, Atradius warns that other suppliers could fall into the same trap by focussing all their sales on other automotive manufacturers that are also going through tough times.
Clark adds: "The motor industry is struggling worldwide.
Dealers are slashing price tags to sell cars, so makers are being forced to cut their own prices, whilst coping with high labour and manufacturing costs.
"As a result, car companies are turning to component makers and original equipment manufacturers in China, India and the Far East to save money, which puts the squeeze on firms here and in Europe.
In fact the only real growth areas in the automotive industry are specialist suppliers and the booming after-sales market selling bolt-on equipment for drivers souping up their cars." The Atradius Automotive Industry Risk Index has been published to help firms in the auto industry identify the potential trading and cash flow problems they face.
Atradius says that in such volatile times, companies must apply stringent credit management, insuring themselves against bad debt, credit checking customers and ensuring prompt payment of invoices.
The key points of the latest Industry Risk Index include: * Vehicle manufacturers - the collapse of MG Rover marked the end of British owned high volume car making in the UK, although production has also ended of the now Ford-owned Jaguar marque at its birthplace in Coventry.
Poor sales of the Jaguar brand are adding to Ford's woes, particularly in the US where its share of the market has fallen from nearly 26% to less than 20% in the last decade.
However GM sales have suffered even further, with its market share slipping from almost 33% in 1995 to less than 26% this year.
Those declines have been matched by growing sales of foreign car makers in the US, particularly by Toyota, Nissan and Honda.
* Car sales - new UK car registrations fell by just 0.5% in 2004 over record highs in 2003 of 2.6 million vehicles.
However, only the big car dealerships such as Reg Vardy, Lookers and Pendragon have really benefited, as they are able to use their massive buying power to cut deals with the manufacturers and incentivise customers with offers.
* Component and original equipment manufacturers (OEMs) - cheap imports are doing the greatest damage to UK and European suppliers - a UK-produced car battery costs GBP 9.95 compared with a product imported from South Korea for GBP 3.50.
A number of UK component makers went to the wall after the collapse of MG Rover, a trend that could continue as more manufacturers source their castings and trims from India and China.
Ford, for example, now gets 50% of it supplies from low-cost countries.
* After market - the traditional parts market for DIY mechanics is in demise as the increasing complexity of car design means that motorists can no longer work on their own cars.
However the so-called 'boy-racer' market is booming as owners, mostly young men, spend thousands of pounds on alloy wheels, audio systems and lighting in an attempt to make their 'bog-standard' (bog-standard equals 'standard' - Ed) hatchbacks look fashionable.
* Niche firms - specialist niche firms provide an industry bright spot, often supplying the small but lucrative market of low-volume high-performance cars and motor sport derived vehicles.
These suppliers usually have the ability to take products from prototype to final product quickly and efficiently.
The full Atradius Automotive Risk Index will be available to download from our website during the first part of August.
Atradius credit insurance not only covers customers for up to 90% of any bad debt, it also carries out initial credit checks on new customers and provides market intelligence on over 45 million individual businesses, industry sectors and markets around the world, with offices in 40 countries providing direct local experience and knowledge.
Credit insurance is ideal for any size of business, from multi-nationals through to SMEs and start-up businesses, and policies are available to cover trading risks in the UK and internationally.
Atradius also provides debt collection services in the UK and overseas, securing repayment in the most efficient and effective way possible.
Wednesday, July 29, 2009
CNC laser profiler speeds cabinet production
George Barker and Company has installed a high-speed automated laser cutting system from LVD to improve productivity and add greater flexibility and capacity to its manufacturing operation.
George Barker designs, manufactures and installs refrigeration units for chilled food, frozen food, specialty display and modular units.
In 2008, the company was awarded the ISO 9001:2000 quality assurance accreditation and is currently being assessed for ISO 14001 environmental standards.
The need to consistently meet high-quality standards and operate more cost effectively, coupled with a strategic group investment plan, has led work study officer, Derek Bower, in search of new sheet metal fabrication equipment.
Bower and his team first considered a CNC punch press to add capacity to existing punching equipment, but soon realised that a laser cutting system would provide greater flexibility in processing the contours for its refrigeration units.
The team researched four major equipment suppliers for six months before selecting the LVD Axel 4020 laser cutting system.
They looked for large table capacity, high-power laser and automated material load and unload.
Aside from product specifications, the team also looked for a vendor with which they could establish a long-term relationship.
The Axel 4020 laser system was selected because of its capacity to handle large sheet sizes up to 4m x 2m and to operate with reduced manpower.
LVD was chosen because of its reputation as a solution provider.
The Axel 4020 is based on a modular design; the machine is standard with integrated shuttle tables.
The shuttle table format allows one table to be loaded while the machine is cutting on the other table, maximising uptime with a changeover time of just 24 seconds.
The team chose to add an automatic load/unload unit to enhance machine productivity by eliminating manual material handling.
The load/unload device handles sheets up to 1000kg and is fully integrated and programmable.
This system option allows George Barker to reduce labour requirements, a critical consideration for Bower and his team.
The laser system also incorporates a number of features that facilitate unattended operation.
A built-in capacitive height sensor automatically maintains a constant distance between the head and the plate, automatically compensating for any uneven material without operator intervention.
The NC Focus provides programmable adjustment of the focal position, eliminating the need for the operator to adjust the focal position.
The selection of a high-power 5kW resonator gives the company the option to cut both thick and thin materials at maximum feed rates.
The high beam quality of the machine allows processing of thin material at speeds up to 40m/min and thick material up to 25mm mild steel with quality surface finishes.
The company currently processes primarily galvanized steel or mild steel in material thicknesses from 0.5mm to 3mm.
The high-speed laser machine combined with the material handling system allows a continuous, even flow of work, achieving a consistent level of throughput and a 50 per cent improvement in productivity.
In addition, the machine's large sheet handling capacity allows for better material utilisation and the nesting of parts, contributing to overall productivity.
Beyond the advantages of automated, high-speed processing, the laser has given George Barker greater flexibility in product design.
Product designs range from half-glass and full-glass frozen food units to medium-sized refrigerated display units designed to be easy to move.
The company's display units are engineered for maximum energy efficiency, display ratio (the ratio between the food display area and the total area the cabinet), modern appearance, merchandising and ergonomics.
The flexibility of the laser system means design flexibility for George Barker is virtually limitless.
Plus, high-quality parts are processed in one operation on the laser.
The quality of the laser-processed parts eliminates time-consuming grinding and finishing operations and adds to a better bottom line with more cost-effective production.
The laser source, CNC, PLC and motors are integrated and interfaced as a complete system to optimise machine performance, offering high speed and reliability, plus low operating and maintenance costs.
As Bower and his team become more familiar with the operation of the laser system, they are finding new ways to maximise the machine's capabilities.
Metal Processes invests in Bystronic laser cutters
Metal Processes, a flat bed laser-cutting sub-contractor, has ordered a Bystronic Byvention laser cutting system and a Bystronic Byspeed laser cutting system.
Bystronic advised Metal Processes to buy the Byvention because of its cutting area of 1562 x 772mm and, when equipped with the 2.2kW resonator, its ability to cut a maximum sheet thickness of 4mm for aluminium, 6mm for stainless steel and 8mm for mild steel.
The machine is operated via pre-defined programs and cutting parameters via a touch screen, making it easy to use.
It features simple and logical operation and users can operate the machine to its full capacity after a short period of training.
When equipped with the 2.2kW resonator, the Byvention requires just 6000 x 6000mm of floor space, which made it the ideal choice for Metal Processes.
John Hayward, chairman and director of Metal Processes, said: 'The production outputs we are achieving per square metre of machine space makes the Byvention a very productive laser-cutting system.
'It is very easy to set up and also very accurate, which is essential to our business.
'A standard laser beam travels all over a 3 x 1.5 metre machine bed, which can affect accuracy depending on the distance travelled by the light beam.
'The beam on the Byvention only has to travel 750 x 1500mm, which makes it accurate.
'In addition, the fact that the Byvention has only two laser mirrors reduces the cost of consumables.' Metal Processes bought a Byspeed laser-cutting centre just months after investing in the Byvention.
The Byspeed is Bystronic's fastest laser-cutting machine and can cut 600 holes per minute, with simultaneous accelerations of more than 4G.
Hayward added: 'Our two Bysprint lasers were six years old and we have had many hours of cutting out of them, having run multiple shifts.
'However, we were conscious that they were costing money to maintain each year and we felt that in this economic climate it was prudent to reduce and even eliminate our variable costs.
'We took the decision to replace both the Bysprint lasers with the single Byspeed laser-cutting centre, which provides greater productivity.
'Having a new machine, with an excellent warranty and service cover, along with a new machine purchased eight months ago (which has the majority of its warranty remaining) made economic sense, drastically reducing our variable maintenance and breakdown costs.' The Byspeed 3015 is equipped with a 4.4kW resonator.
Metal Processes has also bought a wide range of Bystronic press brake tools, which can bend various types of material in thicknesses ranging from 0.5 to 8mm.
Metal Processes has a history of buying Bystronic laser-cutting systems, dating back to 1998.
Two Bystronic Bysprint laser-cutting systems followed in 2002/03 and a Bystronic AFM EP press brake in 2007.
CNC combination machine improves productivity
Amada UK has announced that Hallmark Sheetmetal has acquired an Amada LC2012 C1 laser/punch CNC combination machine with integrated automation - the first of its kind to be installed outside of Japan.
Hallmark Sheetmetal traded-in its existing Amada X1 laser-profiling centre in exchange for the C1 combination machine.
The C1's in-line MP-C1 automated load/unload system offers Hallmark the ability to run unmanned day and night.
Furthermore, the additional punching and forming capability provides the company with the potential to complete parts on a single machine.
Paul Martin, managing director at Hallmark Sheetmetal, said: 'It's no secret that punching is faster than laser cutting when it comes to the use of standard tooling to produce repeat features.
'For this reason we now punch as many features as we can on our C1 to achieve better cost-per-part, while for aesthetic profiling we use the laser, or on apertures for which we have no tool.'
There are other benefits that Hallmark now enjoys as a result of its acquisition, such as reduced consumption of liquid nitrogen and a compact footprint.
The LC-C1 punch/laser combination machine comes with a range of features that include an energy saving single AC servo-drive motor that provides 20 tonnes of variable punching stroke.
Other benefits include: a quick-change nozzle assembly; a quick-change lens assembly; Amada's AMNC windows-based, network-ready control; and a 49-station MPT turret for flexibility and rapid set-up.
The MPT turret also allows the use of 'drop-in' style tapping tools from M2.5 up to M8 in size.
Furthermore, lift-up stations eliminate material marking due to high dies, while a floating brush table ensures punched down-forms do not catch on dies.
Martin said: 'Since it was installed in February, our C1 has been busy helping us tackle a new contract we recently secured from a blue-chip customer.
'The machine's sheet size (the C1 is available in 1270 x 1270mm and 2000 x1270mm bed sizes) and functionality, particularly the three active die stations for enhanced forming capability, have provided the opportunity to improve our margin.'.
LVD enhances Axel 4020 with load/unload system
LVD has added the option of a load/unload system to its Axel 4020 laser-cutting system, providing continuous, uninterrupted dynamic laser-processing of sheets up to 4 x 2M.
Axel 4020 combines linear drive technology, laser power and control systems for large sheet processing.
The load/unload system can be easily retrofitted at any time and handles sheets up to 1000kg.
It allows loading and unloading functions to be performed independently, with a plate-to-plate changeover time of just 29 seconds.
Integration of the load/unload system permits unattended production, freeing the operator to perform other tasks.
The Axel 4020 machine and load/unload system feature a modular design, providing maximum efficiency in material handling while minimising the required floor space.
The loading station is equipped with spreading magnets, a peeling cup to separate non-ferrous material and a sheet-thickness measurement device.
The loading mechanism moves only in a vertical direction for quick and safe loading of sheets from the loading station.
The system is controlled through a single integrated and intuitive touch-screen CNC control.
The high beam-quality of the resonator allows processing of thin material at speeds up to 40m/min and thick material up to 25mm mild steel with high-quality surface finishes.
The laser source, CNC, PLC and motors are integrated and interfaced as a complete system to optimise machine performance, offering high speed and reliability and low operating and maintenance costs.
Laser cutting provides better gas flow
In several development steps with cutting trials, Precitec has increased the flow rate through the cutting nozzle while keeping the cutting gas pressure constant.
The KT B CON ceramic part and the nozzles now have no 'hard edges' and have a conical geometry.
Thus, the cutting gas pressure can be reduced while giving the same cutting edge quality and the input pressure directly on the processing head can be reduced.
The company said that field tests with the new design have also shown an increased working range for the focal position.
Dirt on the focussing lens and the associated focus shift can be detected with the larger process window and increase the operating life of the optics.
With CO2 cutting heads without a protective window in particular, this leads to cost advantages.
Novacel develops protective film for sheet metal
Novacel, which specialises in industrial surface protection, particularly for uncoated metal, has unveiled the 4226REN protective film for sheet metal, according to the French Technology Press Bureau.
This film is suitable for protecting metal, such as stainless steel, during laser cutting.
It will not peel off or form air bubbles during cutting and stainless steel is protected from discolouration through laser cutting.
The film can be printed with brushing or polishing directions and cutting patterns to allow the sheet metal to be laser cut in a single run.
It has an outdoor resistance of six months and peels off in one piece without tearing.
The 4226REN film reduces laser cutting time and maintains surface integrity throughout the mechanical transformation cycle on parts being cut (bending, backing, stamping and forming).
The film's material prevents any risk of suction between pieces of sheet metal during automated handling.
This film is free of harmful chemicals.
As with the entire Novacel range, 4226REN is recyclable.
The colour of the product is white and the film type is UV-resistant LDPE (low-density polyethylene).
It has a thickness of 100 microns and adhesion strength (AFERA 4001) of 140cN/cm.
The adhesive type is natural rubber and lengths of 1,000m and 500m (3,280ft and 1,640ft) are available.
Custom printing samples are available on request.
LVD has introduced Sirius, an automation-ready flying optics laser-cutting system
Sirius provides efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio.
Sirius is offered in a standard and a 'Plus' model.
Sirius provides quick and precise positioning and consistently accurate laser processing.
The combination of a dynamic machine with an excellent laser-beam quality allows high-speed laser cutting.
Quick positioning is achieved with axis speeds up to 120m/min.
Sirius is designed with a modular construction, permitting the user to select the configuration that works best for their application and budget.
As a standard unit, the laser-cutting system features 3 x 1.5m integrated shuttle tables, which maximise uptime by allowing one table to be loaded while the machine is cutting on the other table.
Table change time is a mere 25s.
Sirius Plus is engineered as automation-ready and can be expanded with the addition of various components to form an automated load/unload system.
An optional compact tower-system creates a productive and flexible manufacturing cell that can be operated 'lights out'.
The tower system, working with the material-handling unit, provides full capabilities for loading and unloading and includes a shelving unit for storing raw material and finished parts.
Sirius is equipped with a laser cutting-head that accommodates a five or 7.5in quick-change lens for fast changeover and minimal set-up.
These water-cooled lenses can be exchanged easily, using a self-centring system.
Lens calibration is programmable and quick to achieve.
The Sirius Plus model offers NC Focus for programmable adjustment of the focal position without operator intervention.
This model also provides process control for piercing and cutting and an automatic shut down feature.
Sirius is equipped with a high-pressure cutting head that produces exceptionally clean cuts.
A crash-protection system protects the head from damage after collision with the workpiece.
A total power-control feature automatically adjusts the laser power in relation to the cutting speed, ensuring an optimal cut at every contour width and minimising the heat-affected zone.
The machine's edge-function feature processes sharp corners cleanly, particularly in thicker materials.
Like all LVD laser-cutting systems, the Sirius series employs the Fanuc GE RF excited fast axial flow CO2 laser.
Sirius is available with a powerful 2.5 or 4kW CO2 laser.
The laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability and low operating and maintenance costs.
The integrated Fanuc GE PC-based control provides perfect reproduction of programmed contours, producing acute angles at high speed.
The laser power is matched to the vectorial speeds to achieve a constant cut-width and a small heat-affected zone.
All parameters, diagnostic and start-up procedures are conveniently displayed on the screen.
The 32-bit control features powerful mathematical capabilities and an extensive material library.
Optional Cadman-L 3D offline programming software provides a comprehensive laser-cutting CAM package.
This includes an integrated 3D design and unfolding module, which allows easy importing of 2D and 3D designs and automatic unfolding and generation of flat patterns from 2D or 3D files.
Cadman-L 3D also incorporates automatic, semi-automatic or manual nesting and optimises cutting and machine parameters to maximise sheet utilisation.
Advanced features include cutting-path optimisation, common line cutting and high-speed communications via Windows, networking or DNC link to maximise machine productivity.
Friday, July 24, 2009
ESAB launches CNC plasma-arc cutting power source
ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.
The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.
The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.
High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.
Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.
Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.
Cutting and marking operations can be carried out with the same consumables.
The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.
The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.
The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.
High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.
Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.
Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.
Cutting and marking operations can be carried out with the same consumables.
The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.
Friday, July 17, 2009
Friedman Industries
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Friedman Industries located its steel coil processing plant adjacent to a steel mill to increase productivity and lower operating costs. |
Friedman Industries Inc. recently opened a new steel coil processing plant located in Decatur, Ala. The facility converts hotrolled coils received from the adjacent Nucor Steel Co. mill into hotrolled sheet and plate relieved of distortions commonly associated with coiled steel through the use of temper-passing and leveling equipment.
Temperpassing and leveling result in significantly flatter and more consistent steels, with the improvements becoming even more pronounced in higher-strength alloys. The cost- and timesaving benefits of Friedman temper-passing and leveling capabilities have become increasingly important where higherstrength materials and tighter tolerances are best handled using today’s more precise, more expensive plasma and laser cutting CNC equipment.
http://www.americanmachinist.com/304/Issue/Article/False/84594/Issue
Wednesday, July 15, 2009
Massive oxy-acetylene gantry profiler doubles throughput for large parts
Spain's Oxyser has dramatically increased the throughput of its oxy-acetylene steel cutting machinery, and automated the process, by developing a new twin-head machine controlled by NUM's Axium CNC platform. In total, the CNC controls 16 motor axes to manage the motion of a gantry with two positioning heads - each fitted with mobile oxy-acetylene cutting torches.
The machine has just been commissioned at Grupo Ros Casares' plant in Aviles, Spain – the company is the Spanish leader in industrial distribution and logistics, steel service centres and structural steelwork.
The new machine is used initially to produce steel plate sections required to construct wind turbine generator towers. The shaped plates are generally cut with bevelled edges so that they can be welded together easily on site.
The parallel worktables - one for each tool head - are 26 metres long, and eight metres wide. The gantry supports two cutting tool heads, with one slave tool following the motion of the master tool. The 4.2 cm thick steel plates being cut for the current wind turbine application typically weigh around eight tonnes each, measure around 10 x 2 metres, and have bevelled edges. To meet the end user's production requirements, the machine currently operates for 16 hours a day. During this period it cuts up to 32 steel plates. The high degree of automation of the cutting process supported by Oxyser's machine means that just one operator is needed, both to run the machine and remove offcuts. The new machine more than doubles throughput.
Believed to be the first of its kind, the machine introduces automatic programmed control of shape cutting in an application sector that is use to much simpler machines: traditionally, only three CNC-controlled axes are employed and the initial positioning of the oxy-acetylene tool for linear cuts is performed manually.
Oxyser developed the new-generation cutting machine to improve productivity for Grupo Ros Casares, and although the cutting capability of the machine's oxy-acetylene torch heads were conceived with the versatility needed to produce bevelled edges for the cladding of wind turbine structures, the machine will cut virtually any complex shape defined by a CAD program.
A specialisist in producing plasma and oxy cutting machines, up to now Oxyser has typically produced smaller systems with up to five axes of control. This project marks the company's entry into the high-end cutting market.
The key technical requirement to meet the demands of this application was a much more powerful CNC. NUM provided a solution in the form of its Axium platform, which offered the computational power to control the 16 axes of motion required. NUM was also able to provide all of the ancillary automation components required for the application including drives, motors, I/O and HMI panel.
http://www.machinery.co.uk/article/19149/Massive-oxy-acetylene-gantry-profiler-doubles-throughput-for-large-parts.aspx
The machine has just been commissioned at Grupo Ros Casares' plant in Aviles, Spain – the company is the Spanish leader in industrial distribution and logistics, steel service centres and structural steelwork.
The new machine is used initially to produce steel plate sections required to construct wind turbine generator towers. The shaped plates are generally cut with bevelled edges so that they can be welded together easily on site.
The parallel worktables - one for each tool head - are 26 metres long, and eight metres wide. The gantry supports two cutting tool heads, with one slave tool following the motion of the master tool. The 4.2 cm thick steel plates being cut for the current wind turbine application typically weigh around eight tonnes each, measure around 10 x 2 metres, and have bevelled edges. To meet the end user's production requirements, the machine currently operates for 16 hours a day. During this period it cuts up to 32 steel plates. The high degree of automation of the cutting process supported by Oxyser's machine means that just one operator is needed, both to run the machine and remove offcuts. The new machine more than doubles throughput.
Believed to be the first of its kind, the machine introduces automatic programmed control of shape cutting in an application sector that is use to much simpler machines: traditionally, only three CNC-controlled axes are employed and the initial positioning of the oxy-acetylene tool for linear cuts is performed manually.
Oxyser developed the new-generation cutting machine to improve productivity for Grupo Ros Casares, and although the cutting capability of the machine's oxy-acetylene torch heads were conceived with the versatility needed to produce bevelled edges for the cladding of wind turbine structures, the machine will cut virtually any complex shape defined by a CAD program.
A specialisist in producing plasma and oxy cutting machines, up to now Oxyser has typically produced smaller systems with up to five axes of control. This project marks the company's entry into the high-end cutting market.
The key technical requirement to meet the demands of this application was a much more powerful CNC. NUM provided a solution in the form of its Axium platform, which offered the computational power to control the 16 axes of motion required. NUM was also able to provide all of the ancillary automation components required for the application including drives, motors, I/O and HMI panel.
http://www.machinery.co.uk/article/19149/Massive-oxy-acetylene-gantry-profiler-doubles-throughput-for-large-parts.aspx
Sunday, April 19, 2009
Big TVs the latest in federal meddling
Libertarians can be a cranky lot, but it is becoming not as hard to sympathize with them as government agencies of every variety flex more of their regulatory muscle in areas that seem to be functioning reasonably well on their own.
The latest example is a proposal by the michigan Energy Commission to impose energy limits on new televisions, the large LCD and plasma TVs that seem to be popping up in every living room and bedroom. In plenty of cases, they are replacing perfectly functional 36-inch tube TVs from a few years ago, which are now selling for next to nothing on the used market.
The commission says a 42-inch plasma screen uses over the Trinitron it replaces, even over a large refrigerator. So it wants to impose energy-saving standards that most TV manufacturers are not ready to meet and that eventually will increase purchase prices.
As with most things, there's at least seven sides to this discussion.
While the size and makeup of our TVs would not seem to be of legitimate concern to government agencies, the Energy Commission does have jurisdiction of a sort because it is responsible for making the best use of California's limited energy supply — and because the government seems to find jurisdiction wherever it looks.
Some sharp engineers calculated long ago that spending cash to reduce energy use can be much cheaper than building new power plants. That's why the state Public Utilities Commission has required utility
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companies to provide consumers with rebates for appliances with low energy demand and why the commission required Pacific Gas & Electric Co. to insulate some homes for free.
Perhaps the rebate technique — a carrot than a stick — explains why there has been relatively little resistance to the mandates involving washing machines and dishwashers. Rebates have been used, with less success, in the arena of water-saving appliances, including those sometimes-ineffective low-flow toilets, another gift from a creative bureaucracy.
Despite that negative example, rebates could be the way to be going with TVs, . than require all TV makers to find ways to cut power use, reward the ones that can do it by helping consumers buy their product. The cash could come from the power-plant construction fund. With reduced operating costs, some extra-efficient TVs could prove real bargains.
Even so, they suspect that legislating the size or shape of TVs will be a more contentious technique than limiting the power used by your new Kenmore stackables. It may be a competitive thing. We've heard no one boast about the cubic feet in their fridges or the number of RPMs reached during their spin cycles, but a 50-inch screen clearly bestows bragging rights when the brother-in-law can only afford 42 inches.
If limiting the power consumption of TVs means limiting the screen size, the regulators might as well be trying to legislate horsepower or, in some households, firepower. Somehow, it may seem like telling us how much they can eat, how much heating or air conditioning they can use, or even how big our couch can be. Maybe even when they can and cannot watch. No "Wheel of Fortune" at times of peak power demand.
In most homes, TVs sit at center stage, unlike washers and dryers. they buy them with an eye to the numbers — inches, of coursework, but also resolution numbers like 1080P, which apparently is better than 720P and presumably much better than numbers like 540P that might emerge from the commission's rule book. What's the point of a bigger screen if it's fuzzy?
The state commission is expected to vote on the proposal during the summer, although no date has been scheduled. There will be workshops and public comment, as there were before the government and the industry embarked on the current conversion to all-digital broadcasting. and if you've enjoyed watching that confusing, on-again, off-again technique unfold for a few years now, you may also enjoy what the Energy Commission may come up with.
The latest example is a proposal by the michigan Energy Commission to impose energy limits on new televisions, the large LCD and plasma TVs that seem to be popping up in every living room and bedroom. In plenty of cases, they are replacing perfectly functional 36-inch tube TVs from a few years ago, which are now selling for next to nothing on the used market.
The commission says a 42-inch plasma screen uses over the Trinitron it replaces, even over a large refrigerator. So it wants to impose energy-saving standards that most TV manufacturers are not ready to meet and that eventually will increase purchase prices.
As with most things, there's at least seven sides to this discussion.
While the size and makeup of our TVs would not seem to be of legitimate concern to government agencies, the Energy Commission does have jurisdiction of a sort because it is responsible for making the best use of California's limited energy supply — and because the government seems to find jurisdiction wherever it looks.
Some sharp engineers calculated long ago that spending cash to reduce energy use can be much cheaper than building new power plants. That's why the state Public Utilities Commission has required utility
Advertisement
companies to provide consumers with rebates for appliances with low energy demand and why the commission required Pacific Gas & Electric Co. to insulate some homes for free.
Perhaps the rebate technique — a carrot than a stick — explains why there has been relatively little resistance to the mandates involving washing machines and dishwashers. Rebates have been used, with less success, in the arena of water-saving appliances, including those sometimes-ineffective low-flow toilets, another gift from a creative bureaucracy.
Despite that negative example, rebates could be the way to be going with TVs, . than require all TV makers to find ways to cut power use, reward the ones that can do it by helping consumers buy their product. The cash could come from the power-plant construction fund. With reduced operating costs, some extra-efficient TVs could prove real bargains.
Even so, they suspect that legislating the size or shape of TVs will be a more contentious technique than limiting the power used by your new Kenmore stackables. It may be a competitive thing. We've heard no one boast about the cubic feet in their fridges or the number of RPMs reached during their spin cycles, but a 50-inch screen clearly bestows bragging rights when the brother-in-law can only afford 42 inches.
If limiting the power consumption of TVs means limiting the screen size, the regulators might as well be trying to legislate horsepower or, in some households, firepower. Somehow, it may seem like telling us how much they can eat, how much heating or air conditioning they can use, or even how big our couch can be. Maybe even when they can and cannot watch. No "Wheel of Fortune" at times of peak power demand.
In most homes, TVs sit at center stage, unlike washers and dryers. they buy them with an eye to the numbers — inches, of coursework, but also resolution numbers like 1080P, which apparently is better than 720P and presumably much better than numbers like 540P that might emerge from the commission's rule book. What's the point of a bigger screen if it's fuzzy?
The state commission is expected to vote on the proposal during the summer, although no date has been scheduled. There will be workshops and public comment, as there were before the government and the industry embarked on the current conversion to all-digital broadcasting. and if you've enjoyed watching that confusing, on-again, off-again technique unfold for a few years now, you may also enjoy what the Energy Commission may come up with.
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