CNC Plasma Cutting

Mig Welders And Other Automotive Service EquipmentMig Welders And Other Automotive Service Equipment

2010-12-14T07:37:00.001-08:00

Ask anyone in the industry what the hottest equipment is in the world of automotive service equipment and they'll name items such as plasma cutters, mig welders, and other welding equipment. And, when you try them out and discover the quality of the cuts and welds they make, it's no surprise. This equipment is a cost-effective and easy-to-use option when compared to the work done by earlier technology.

Mig Welders And Other Automotive Service Equipment

This type of equipment comes in a number of convenient types to repair or make almost anything quickly and easily. With these machines, you'll look like a seasoned professional. All you need to do is match the machine to the work you're doing.

Arc Style Machines

The earliest advancement on the traditional torch, arc welders are an entry level of automotive service equipment that are also some of the easiest to use. More commonly known as stick welding, this unit joins thick metals together quickly using an electrode and electric arcs.

Mig Welders

The next step up from an arc welder, mig welders, use a wire feed and produce a lower heat. This prevents metal distortion and allows you to do a higher quality job on thinner metals such as those involved in auto body work.

Mig welders feed a constant stream of wire with a pull of the trigger, but you'll still need to choose your supplies carefully. Wire, for example, comes in easy-to-use flux core wire for a quick job on thicker materials, or a gas/solid wire combination for all other work.

The type of gas you use also makes a significant difference on the weld quality. Argon and CO2 are best for stainless steel and aluminum. To prevent the wire feed from sticking on the weld line, be sure to use a Teflon liner. Finally, you'll need to choose the appropriate wire diameter and tip size.

Once you've chosen the appropriate automotive service equipment, you'll still want to practice on scraps before working on the final piece for the best results. This is particularly true for aluminum and other delicate materials. Also, don't be afraid to watch the gauges and flow meters on the supply lines as well as on the machine itself. In the end, you'll find mig welders quick and affordable while still doing a quality job.

Tig Or Tungsten Inert Gas

Unlike the first two machines mentioned, this style requires a combination of heat and tungsten electrodes to work. One of the biggest advantages to this style of welder is the fact that it heats and joins the two metal pieces together without the need for filler materials. The only exception is argon or other gasses needed to create the shielding.

You'll notice that mig welders join metals together much faster than tig welders. However, tig welders work with higher precision and accuracy, which is great for customized work. Tig machines require more skills and practice to use properly. The possibility of preventing cracked seals or damaging the weld is also significantly decreased.

Plasma Cutters

There's no denying the precision of plasma cutters. To get clean, accurate cuts, these units use an electric arc and gas/air at a high pressure, along with a high-speed wire and low heat setting. You'll also notice that newer lines of plasma cutters have an inverter in place of the transformer. This keeps the temperature of the machine lower and makes it possible to have smaller, lighter machines without jeopardizing safety or quality.

With all of the different styles of plasma cutters available, you'll want to choose carefully. Duty cycle should be one of the main determining factors in your decision. This determines how long you can use this automotive service equipment before having to allow it to cool. Generally, you'll discover that bigger machines can handle thicker metals and run longer to give it a bigger duty cycle.

The other important feature you'll want to make note of is the rating that is assigned to plasma cutters by the manufacturer. This will tell you how long each unit can cut through mild steel before needing to be cooled down. The rating varies, however. If you're working on tempered steel, the length of time you have to make the cut will be far lower. Aluminum, on the other hand, is far easier to cut, and therefore gives you more operating time to work with.

Features Found On Mig, Tig, Arc & Plasma Cutters

Arc Welders

Arc welders are packed full of helpful features to improve the precision of this automotive service equipment and make them easier to use. Unlimited amperage control means you have the ability to create professional welds. Their lightweight and super-sturdy design makes this type of welder highly portable and durable enough to withstand regular wear. You'll also find that some models of arc welders have thermostatic heat protection and a roll bar design to give the unit increased protection against damage.

Mig Welding Equipment

Ranging in size from a small, portable 115v, 20 amp machine to full sized shop automotive service equipment, mig welders are one of the few that combine a relatively low price tag with high quality performance. You can also gain full control over the quality of the weld with a full range of settings. Finally, these machines come with added benefits such as colder running temperatures and some of the best warranty options.

Tig Welders

Even the most basic tig welding machines come loaded full of features. Push button control panels make them easier to use while higher end models let you easily adjust the machines repeatable weld cycles, start, and weld crater. To customize the shape and size of the bead, look for models with true square wave AC output and pulse mode. Lastly, look for models with added safety features such as warning code circuitry and voltage protection.

Plasma Cutters

Like the welders mentioned previously, plasma cutters come with a full range of features. Single-dial controls for quick adjustments, pressure gauges, and built in air pressure regulators put you in full control of this automotive service equipment and result it cleaner cuts.

Additional features such as parts-in-place indicators, line voltage compensation, and thermostatic protection add to the safety of plasma cutters. Finally, if you'll be doing repetitive work with complicated cuts, CNC robotic interfaces on your automotive service equipment will ensure you get consistent, accurate results every time.

Automotive service equipment like mig welders and plasma cutters come in a variety of different types with many different features to get you the best cut or weld possible. In order to achieve the cleanest, most precise repairs, you simply need to match the right automotive service equipment to the job.

Chris Harmen is a writer for ASE Deals, America's top choice for automotive service equipment. ASE Deals offers competitive prices on all tools and repair equipment including mig welders, air compressors, auto lifts and more.

Article Source: http://EzineArticles.com/?expert=Chris_A._Harmen

Information For the Manufacturing Engineer

2010-12-14T07:36:00.001-08:00

As a manufacturing engineer one must be familiar with all the available manufacturing processes. In this article we will be discussing water jet cutting and how it can be used to improve your manufacturing process. Waterjet cutting at its simplest form is a jet of water at a very high pressure that abrasively removes material. This water usually has an abrasive material such as Garnett added to aid in the abrasive material removal qualities.

It works by pressurizing water up to 60,000 psi, and forcing it through a tiny opening Waterjets are capable of cutting a variety of materials with CNC accuracy. Typical part tolerances range from between 0.005 and 0.010 of an inch. When small amounts of abrasive particles, such as garnet, are mixed into the jet stream, the resulting "abrasive waterjet" can cut virtually any hard material such as metal, composites, stone and glass.

Waterjet Cutting vs. Lasers
Laser cutting is a very productive process and certainly has its place. However, Waterjets do have several advantages over lasers:

There are no thickness limitations. A typical 1500 watt CO2 laser is limited to about .625" thick steel plate. There are no problems cutting with reflective materials such as Brass, Copper and Aluminum. There is no heat output, so there is no heat-affected zone (HAZ). Waterjets can cut materials, which are heat sensitive such as plastics, rubber or composites.

Waterjet vs. Plasma
Plasma removes material around 5800 deg f. leaving a large heat-affected zone. The surface finish of plasma generally is very course with a lot of slag. This slag requires secondary operations to remove where water jet cutting does not. Abrasive Waterjets have no thickness limitation, and can be much more closely nested.

What tolerances can we expect from waterjet cutting?
The accuracy you will get Typically +/- .010" but depending on part size and part thickness.

How thick can it cut?
Typical waterjet's can cut up to 8.00" in thickness depending on material type and hardness.

What materials cannot be cut?
Almost any material can be cut by water jet. There are some exceptions that can prove to be difficult; these materials tend to be laminated in construction. Test cuts have resulted in delaminating.

How thick is the Kerf?
The Kerf is about 10% of the diameter of the cutting orifice. If a .040" diameter tip is used Kerf is around .043" in diameter.

What is the minimum radius/ diameter that can be cut?
The radius limitations are dependent on the diameter of the orifice being used and are equal to the Kerf diameter. Using a .040" diameter tip the minimum radii and hole diameter will be around .043".

What taper can I expect?
The taper you get is a function of the cut speed. However, the worst taper you will get will be equal to the maximum Kerf width at the top (example: 0.043") and 0.000". At the bottom. As you slow down the taper will be reduced until you get parallel sides.

What fixturing is required?
Since the force exerted on the work piece is very small (under 5 lbs. for average cuts), the need for very large, stiff fixtures is eliminated.

For more information on waterjet cutting services and how they can benefit your manufacturing production visit http://www.e-bti.com.

Brent Cohagan
President
Cohagan Engineering, Inc.
http://www.CohaganEngineering.com

Article Source: http://EzineArticles.com/?expert=Brent_Cohagan

Purchasing Plasma Cutters

2010-12-14T07:27:00.000-08:00

Plasma cutters are an important tool to have when it comes making sure you have the right automotive service equipment to get repairs done right. Like mig welders, this equipment uses electricity and gas to work, but that's where the similarities end. If you're looking to buy plasma cutters for your home shop or commercial garage, this article will explore a few things you should know before making a final purchasing decision.

Types and Features of Plasma Cutters

This type of automotive service equipment comes in three main types:

Compact - Noted for high power in a small, portable package, compact machines like these run off a standard 120V AC outlet, making them ideal for repairs on the go and onsite repairs. They cut everything from aluminum and stainless steel to carbon steel with ease and will remove spot welds almost instantly.

This style also uses a basic air compressor rather than requiring special gases and classes to haul it from place to place. Quality models will come with fans to keep everything cool and extend the life of the machines, built-in regulators with air reducers for total control, electrodes of various lengths, and different nozzles.

Low Amp Plasma Cutters - Low amp automotive service equipment models are similar to mig welders in the fact that they run off either 120 or 230V outlets. You can't beat this type of machine when it comes to cutting stainless, carbon steel, or aluminum, or removing spot welds. They also have built in pressure regulators, easy-to-use control panels, and fans to keep them cool. Larger wheels ensure that they move around far more easily and, because they run cooler, these machines won't over heat and damage the metal. For ease of use, look for models with compact handles, long tips, and longer nozzles, which are designed specifically for tight areas.

High Amp Styles - This type of plasma cutter runs upwards of 85 amps and weighs in at almost 100 lbs. Generally, thought of as stationary automotive service equipment, this style is available in 'engine driven' models or with a 'valet style' undercarriage for improved maneuverability. Machines that include VORTECH technology and dual winding technology give you a fast arc, better cutting speed, and improved performance with superior cutting abilities.

Features such as quick disconnects make it easy to remove and change torches while LED panels and indicators make the system easy to read and control. Other features to watch for include Parts-In-Place and lockout circuits for improved safety. For increased precision, particularly with repetitive or difficult cuts, select plasma cutter models with a CNC/Robotic interface.

Use & Application of Different Types of Plasma Cutters

Once you're aware of the types of plasma cutters you can choose from, you'll need to weigh the benefits of each style in order to determine which type is best for you.

Compact plasma cutter models are ideal for on site repairs of lighter metals of 3/8" or less in thickness. This means that those in auto body, farm, hobby, HVAC, and sheet metal fabrication absolutely love these machines. Additionally, since they run on 110V outlets, you won't be fighting to find somewhere to plug them in either.

Low amp machines are ideal for those industrial uses such as HVAC, light plate, and sheet metal fabrication. They make quick work on metal up to 3/4" thick and have winding technology, lower dross levels, and quick arc transfer rates for easy starts and fast restrikes so that you find it easy to work on even expanded metal.

If you'll be cutting metal up to 1 1/4" thick, you'll definitely need to look at high amp plasma cutters. This style of automotive service equipment is ideal for the most intense, industrial situations. In fact, this style is a favorite model for those working in fabrication, maintenance, and other heavy-duty applications.

Best Plasma Cutters Brands

Lincoln, Thermal Dynamics, and Marquette are just some of the best brands of plasma cutters you can find on the market. However, the reason why these brands have earned that title is far more important.

Warranty is an important aspect of any quality automotive service equipment brand. You want to be sure that the style of machine you purchase comes with at least two years worth of parts. This is vital since these cutters can be extremely expensive to repair. Also, be sure to go with a brand that has been around for awhile in order to improve the likelihood that you'll be able to get parts 10 or 15 years down the road.

ISO certification is also important when identifying quality brands. This system ensures that each machine meets strict industry standards and is tested before it ever leaves the plant. The plant itself is assessed and tested on a regular basis to ensure that it meets standards from start to finish.

Most importantly, make sure that you only purchase from a reputable dealer who offers quality equipment at a competitive price. This will ensure that you get the automotive service equipment that you ordered without worrying that the price is inflated, or that the certification and brand has been faked. You'll get quality equipment and quality customer service, and that's worth the time you take to research machines and dealers.

Chris Harmen is a writer for ASE Deals, America's top choice for automotive service equipment, including plasma cutters, car lifts, motorcycle lifts, welders, auto shop equipment and air compressors. ASE Deals offers competitive prices on all tools and repair equipment.

Article Source: http://EzineArticles.com/?expert=Chris_A._Harmen

CNC plasma-arc cutting power source

2009-09-13T22:57:00.000-07:00

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.

Walter solid carbide cutters machine titanium

2009-08-28T03:18:00.001-07:00

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

2009-08-28T03:17:00.003-07:00

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

2009-08-28T03:17:00.001-07:00

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

2009-08-28T03:16:00.004-07:00

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

2009-08-28T03:16:00.003-07:00

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

2009-08-28T03:16:00.001-07:00

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

2009-08-28T03:15:00.001-07:00

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.

ESAB launches CNC plasma-arc cutting power source

2009-08-21T03:26:00.001-07:00

ESAB introduces Falcon cutting machine

2009-08-21T03:25:00.003-07:00

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.

Autodrill adds option to cutting machines

2009-08-21T03:25:00.001-07:00

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.

ESAB PDM tracks cutting system performance

2009-08-21T03:24:00.000-07:00

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.

PP Plasma uses ESAB submerged plasma cutter

2009-08-21T03:23:00.002-07:00

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.

NUM to exhibit tool head and 3D simulation package

2009-08-21T03:23:00.001-07:00

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.

M3 plasma cutting system offers quick installation

2009-08-21T03:22:00.002-07:00

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.

Brown McFarlane buys ESAB plasma power sources

2009-08-21T03:22:00.001-07:00

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.

Autodrill adds option to cutting machines

2009-08-18T08:59:00.003-07:00

ESAB PDM tracks cutting system performance

2009-08-18T08:59:00.001-07:00

Brown McFarlane buys ESAB plasma power sources

2009-08-18T08:58:00.004-07:00

Plasma-arc developments on display in Essen

2009-08-18T08:58:00.003-07:00

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.

M3 plasma cutting system offers quick installation

2009-08-18T08:58:00.001-07:00

Nano-grain carbide endmills machine hard materials

2009-08-12T08:31:00.002-07:00

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

2009-08-12T08:31:00.001-07:00

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

2009-08-12T08:30:00.004-07:00

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.

Dormer announces rotary tooling products

2009-08-12T08:30:00.003-07:00

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.

Walter solid carbide cutters machine titanium

2009-08-12T08:30:00.001-07:00

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.

Advanced sliding head auto converts subby to OEM

2009-08-04T05:00:00.001-07:00

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

2009-08-04T04:59:00.000-07:00

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 Metalworking

Auto-parts suppliers should look outside

2009-08-04T04:58:00.000-07:00

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.

CNC laser profiler speeds cabinet production

2009-07-29T03:35:00.002-07:00

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

2009-07-29T03:35:00.001-07:00

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

2009-07-29T03:34:00.002-07:00

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

2009-07-29T03:34:00.001-07:00

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

2009-07-29T03:33:00.002-07:00

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

2009-07-29T03:33:00.001-07:00

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

2009-07-29T03:32:00.001-07:00

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.

ESAB launches CNC plasma-arc cutting power source

2009-07-24T21:44:00.001-07:00

Friedman Industries

2009-07-17T04:34:00.001-07:00

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

Massive oxy-acetylene gantry profiler doubles throughput for large parts

2009-07-15T09:09:00.000-07:00

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

Big TVs the latest in federal meddling

2009-04-19T19:40:00.000-07:00

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.

CIGWELD cutting and welding equipment and filler metals

2009-04-07T22:30:00.000-07:00

CIGWELD cutting and welding equipment and filler metals will be the focus of attention on Thermadyne Australia’s stand 4111 during National Manufacturing Week.

According to Cigweld, they account for more than 75% of Thermadyne sales in the South Pacific, making it the company’s market leading branch in the region.

Along with Cigweld products, Thermadyne will also use NMW to actively promote four of its other core brands including: Thermal Dynamics - manual and automated plasma cutting systems, accessories and consumables; Tweco - manual and semi-automatic welding torches, consumables and accessories; Arcair - carbon arc gouging torches and rods; and Stoody - tubular special purpose and hard surfacing wires.

Job losses boost entrepreneurial spirit

2009-03-25T22:55:00.000-07:00

Recession-battered people sell plasma, burial plots, human eggs

After her husband's work hours were cut by about half, Kari Lovings, a 21-year-old stay-at-home mom of seven, signed up to become an egg donor at the North Carolina Center for Reproductive Medicine, a fertility center. If he is picked, she'll earn $3,000 and help a couple unable to conceive.

Cemetery plots. Blood plasma. Human eggs. Whatever they think they can spare, some Triangle residents are selling it to pay bills or to hold off debt collectors.

Tough times have a way of bringing out a person's entrepreneurial spirit, whether it's renting out an unused room, bartering or making fashion with used fabrics.

"It's kind of a big deal," said Lovings. "I've never done anything like this before. But they need any type of money to come in."

And more cutbacks are looming, in areas considered the bedrock of employment, such as government, the universities and public schools.

Even though North Carolinians have yet to experience the extent of economic misery seen in states such as los angeles or Florida, which were hit hard by the housing and mortgage crises, statewide job losses have risen sharply in past months. In January, unemployment in North Carolina increased faster than in most other states, surging to 9.7 percent. Nationwide, 7.6 percent of workers were unemployed in January.

This seemingly bottomless downward spiral brings out a combination of desperation and creativity, said Dan Ariely, a behavioral economist at Duke University: "People are in trouble. They're thinking about things to do."

require to buy a plot?

Then there's plasma.

Ryan Lynch of Montlawn Memorial Park in Raleigh said he's answered more inquiries than usual from people looking to sell their burial plots. In February, over a dozen cemetery plots were for sale on various classified sites in the Triangle area of North Carolina.

"This is $240 a month," Staton said. The money helps pay for food, a pair of shoes or the cell phone bill, as well as the occasional treat.

Bryon Staton, 36, a cook who was laid off from a Raleigh restaurant in November, is selling his blood plasma to stretch his unemployment check. Since October, Staton has been going one time a week to a blood plasma center to help make ends meet.

Pioneer sees wider loss, cuts 10,000 jobs

2009-02-16T22:26:00.001-08:00

PIONEER Corp. will cut 10,000 jobs and close its television operations as the slump in global electronics sales forced the company to widen its annual loss forecast to a record ¥130 billion ($1.44 billion).

The company will withdraw from the TV business by March 2010 and cut 16 percent of its full-time work force, plus 4,000 temporary positions, Tokyo-based Pioneer said. The net loss in the year ending March 31 compares with the ¥78-billion deficit it estimated on October 30. Sales will probably fall 28 percent to ¥560 billion, the company said.

Pioneer, poised for a fifth annual deficit, lost a combined ¥100.6 billion at its home electronics business, including plasma TV operations, since the year ended March 2004. The recession increases the challenge for president Susumu Kotani, who took charge in November, to restore profitability by relying on sales of car-navigation systems even as auto sales plunge.

Pioneer said on May 13 it will stop making its own plasma panels by March to get out of money-losing flat-screen TV production. It ended output at two of its three plants in Japan last year and will halt operations at the remaining factory this month.

The withdrawal ends more than 25 years of TV manufacturing at Pioneer, which shifted its focus from cathode ray tube sets to developing plasma screen models in 1991.

In February 2004, Pioneer, then the world’s fifth-largest plasma panel maker, agreed to buy the plasma-TV operations of NEC Corp., the sixth-largest panel maker at the time.

Liquid crystal display TVs outsold plasma sets once prices became competitive because they offer brighter picture quality.

In the three months ended December 31, Panasonic Corp., Samsung SDI Co. and LG Electronics Inc. had a combined share of more than 90 percent of the global plasma screen TV market, researcher DisplaySearch said. (Bloomberg)

Article Resource:http://businessmirror.com.ph/index.php?option=com_content&view=article&id=6152:pioneer-sees-wider-loss-cuts-10000-jobs&catid=52:technology

Ixonia manufacturer expands with heavy cutting capacity

2009-02-09T22:46:00.000-08:00

Metalcraft Tool & Die Inc., an Ixonia-based tool and die and heavy fabrication shop, recently added a new plasma cutting machine capable of cutting steel plates up to three inches thick.

The new capability makes the company the only manufacturer in the state able to plasma cut material that thick, according to Chris Broege, vice president of the firm.

"We're the first ones in the country to be shipped one of these machines," he said. "It came in about two and a half weeks ago."

The plasma cutter allows Metalcraft Tool & Die to cut steel that would normally require traditional flame cutting, Broege said. Plasma cutting allows for a smoother edge on the finished product, he said, similar to a laser cut piece of steel.

Since moving into heavy fabrication three years ago, Metalcraft Tool & Die has grown from two employees to 15. In January 2008, the company moved into a new 12,500 square foot facility in Ixonia. Because of its growth, it will likely need to add another 10,000 square feet this summer, Broege said.

Metalcraft currently does heavy fabrication for manufacturers of heat treating furnaces and frame chassis used for heavy equipment. The company is hoping its new heavy plasma cutting machine will help it gain new customers in the mining equipment and other industries.

Dispenser designed for modern appeal

2009-01-29T23:17:00.000-08:00

RPC Bramlage has launched the latest generation of its renowned CD dispenser - the CD Smart - offering all of the range’s proven functionality in a stylish new look CD Smart has been designed for modern appeal, with a slim cylindrical body and an hourglass-shaped dispensing head

The appearance of the cap and body can be customised to meet specific branding objectives with a range of decorative options, including hot stamping, silk-screen printing and labelling.

High-quality, environmentally-friendly function is assured thanks to the dispenser’s patented mechanical vacuum operation.

It is available initially in 15 and 30ml sizes and can be injection moulded in PS, PP or PET.

Affordable CNC Plasma & Laser Cutting Machine

2008-09-21T22:43:00.001-07:00

The plasma cutting process uses high velocity as well as high temperature ionized gas along with an arc, to cut different types of materials.

Plasma cutting process

The plasma cutter torch has a high velocity ionized gas that conducts electricity, which is used to heat the work piece and eventually melts the material. While the purpose of the arc is to melt the material with its high heat, the function of the gas is to blow the molten material away from the piece and cut the material. Due to the force of the plasma, you get a clean cut with very little or no slag at all. The plasma arc roughly has a speed of up to 20,000 feet per second (that's more than 13,000 miles per hour!) while the temperature is as high as 30,000º F.

Different types of Plasma cutting machines

Plasma cutting machines are available in a variety of types such as plasma torches, plasma torches, and plasma cutters. Compressed air or nitrogen is used as a cutting gas in plasma cutting torches. The torches have a narrow-width kerf along with a water-cooled electrode. Plasma torches use a high temperature gas steam, which is produced by passing the gas through an electric arc discharge. The plasma torch has two electrodes that are metallic and tubular in nature. The electrical arc flows between the negative or positive electrodes. Plasma cutters are specially used for cutting steel and materials that conduct electricity.

Advantages of Plasma cutting machines

- They provide high quality cuts and fast travel speeds.

- It is a low cost process for short runs as no physical tooling is required.

- A cost effective option for thick metal sheets.

- As compared to laser cutting can cut thicker sheets.

- It can be used to cut a wide variety of geometric shapes along with 2D shapes that do not require too much precision.

Specifications

The process can be used on ferrous and non-ferrous metals and requires only software tooling. It helps to reduce cost by reducing total cut length. At times, some warping may occur on complex parts. The cut edge is somewhat roughened and may show the presence of an oxide layer. Further, the plasma cut surface may not be precisely perpendicular to the surface of sheet material.

eMachineShop offers you information about various types of CNC machines along with other cutting techniques such as Plasma cutting and Laser cutting. Visit the site www.eMachineShop.com to design and order custom plasma cut parts today!

George is a well-known author who writes on the topics related with Injection Molding, Free CAD Software and CNC Milling for the site http://www.emachineshop.com

Article Source: http://EzineArticles.com/?expert=George_Ure

Plasma Cutter Safety - Plasma Cutting Is As Safe As Welding - With A Few Exceptions

2008-08-24T22:20:00.001-07:00

Attention Plasma Cutters! General Welding Safety is not enough.

There are a few things about plasma cutting safety that are different from general welding safety tips

This short list of plasma cutter safety tips is geared toward light duty plasma cutting using compressed air not large industrial units that use gas mixtures and water cutting tables.

Electric Shock Can Kill

- Operating a plasma cutter completes an electric circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

- Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.

Voltages & Currents

- Plasma cutter output voltages are much greater than welding voltages, usually 100-200 volts.

Precautionary Measures

- Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place on the workbench with the work cable attached during the cutting process.

- During plasma cutting operations do not move the work clamp.

Wear insulated gloves and boots, and keep your body and clothing dry.

- Do not stand, sit or lie on or otherwise touch any wet surface when using the plasma cutter system.

- Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

Work Cable

- Ensure metal-to-metal contact between work cable and workpiece or work table.

- Work cable clamp should make contact with clean metal free of rust, dirt, painted surfaces, etc.

- Do not attach work cable to the piece that will fall away when the cut is complete

Plasma cutter Arc Rays

Plasma cutter arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

Protective Clothing

- Guantlet gloves, safety shoes and hat.

- Flame-retardant clothing to cover all exposed areas.

- Cuffless trousers to prevent entry of sparks and slag.

- Remove combustibles, such as a butane lighter or matches, from your pockets before cutting.

Noise Levels of Plasma Arc Cutting

- Plasma arc cutting systems can generate noise levels in excess of 120 dB during high-amperage cutting operations.

- Ear protection should be used when operating or working near plasma arc cutting operations.

Toxic Fumes & Gases

Plasma arc cutting can produce toxic fumes and gases that deplete oxygen and cause serious injury.

- Keep the cutting area well ventilated or use an approved air-supplied respirator.

- Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.

Pacemakers & Hearing Aids

- Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations

Overall Plasma Safety

- The plasma arc cutting process can be very safe.

- By paying attention to safety standards and correctly setting up and operating the system, plasma arc cutting poses no more a threat than most welding processes.

For more information on plasma cutting and other welding information, visit http://www.weldingtipsandtricks.com

Article Source: http://EzineArticles.com/?expert=Jody_Collier

Affordable CNC Plasma & Laser Cutting Machine

2008-08-24T22:20:00.000-07:00

Jay Leno’s Garage Turns to Hypertherm For Plasma Cutting Needs

2008-08-15T20:42:00.000-07:00

Hypertherm plasma cutting brand is the choice for Jay Leno and his professional race team, when it comes to cutting metal during an auto restoration.

The team at Jay Leno's Garage knows that when it comes to fixing up cars-namely Jay's impressive collection of vintage automobiles-there is one plasma cutting brand that rises above the rest: Hypertherm. That is why Jay and the Big Dog Race Team turn to the Hypertherm Powermax30 when cutting metal during an auto restoration.

When it comes to automotive restoration, the team at Jay Leno’s Big Dog Garage looks for the latest in plasma metal cutting technology. Whether it’s to fix an exhaust system on a car, remove a bent or crushed bracket or replace corroded and rusted body panels the team has turned to Hypertherm and the Powermax30 manual plasma system.

Super portable, the Powermax30 can easily cut through metal up to 10 mm thick and sever metal up to 12 mm thick. And all with only 110 or 220 volt power and compressed air.

"The Powermax30 is definitely impressive. I have to admit I was a little skeptical when I first saw it because the unit is so small. I thought there is no way that thing is going to cut through the metal on our cars. But it did with no problem," said Bernard Juchli, head mechanic and race car driver for the Big Dog team. "It didn't even hesitate for a second. It was fast, easy to use, and really produced a nice clean cut."

You can see what Jay and Bernard have to say about the Powermax30 in the garage's latest Under the Hood segment available by clicking here. "The Powermax30 is a great tool," said Juchli. "I would even go as far as saying it is the first tool any auto restoration professional or hobbyist needs for their shop or garage."

Weighing just 9 kg, the Powermax30 is one of the smallest plasma cutters on the market, making it super portable. But don't let the small size fool you. As the old saying goes, "good things come in small packages". The Powermax30 is no exception. Even though it's small, it can easily cut through metal up to 10 mm thick and sever metal up to 12 mm thick. All of that with only 110 or 220 volt power and compressed air.

Whether you need to fix an exhaust system on your car, remove a bent or crushed bracket, replace corroded and rusted body panels, or fix up a floor or frame, a plasma cutter like the Hypertherm Powermax30 is indispensable. First, it is more versatile than any other metal cutting method out there, especially since you can cut both mild steel and aluminum; even if it's rusted, painted or dirty. In addition, patented Hypertherm technology and simple controls make it easy to drag cut with your Powermax system. You can also cut with a standoff (great for odd-shaped pieces or when trying to access a tight location) or make high quality, very narrow cuts on thin material with virtually no warping and a very small heat affected zone.

In addition to cutting, plasma can be used in place of carbon arc gouging to remove metal for weld preparation or for gouging out worn or cracked parts for repair or replacement. Plasma is also great for piercing.

Not only is plasma fast-in fact, much faster than oxyfuel, saws, and shears-it makes nice clean cuts so very little time is wasted on cleaning up cut parts. The combination of speed, superior cut quality, and low cost of operation makes it very popular in auto shops: it saves time which ultimately makes the shops more productive and profitable.

Jay Leno's Big Dog Garage is home to one of the world's great car collections and one of the world's best equipped garages. The 5,181.6 square meters facility was custom-built from the ground up and is run by a team of mechanical wizards adept at fixing, restoring, and customizing just about every type of vehicle imaginable. Since you can't exactly go down to the local auto shop for parts from pre-teen cars, the garage is geared up to fabricate parts and do just about all required work in house: a CNC Mill, a water jet cutter, sheet metal equipment, a lathe, a regular mill, welding equipment and a Hypertherm Powermax30 are among the shop highlights.

Plasma-arc unit offers high cutting

2008-08-15T20:28:00.000-07:00

Kjellberg Finsterwalde will be demonstrating at EuroBLECH its HiFocus 440i plasma-arc cutting unit, which offers highest cutting precision across material thicknesses from 1mm up to 100mm.

Kjellberg Finsterwalde will be showing its latest developments in plasma-arc cutting technology and high efficiency arc welding at the EuroBLECH 2008 sheet metal working exhibition The company's HiFocus plasma-arc technology will be represented by a demonstration of the HiFocus 440i plasma-arc cutting unit Kjellberg claimed that the system offers the highest cutting precision across a full range of material thickness from 1mm up to 100mm.

The new PerCut 450M plasma-arc torch completes the unmatched process flexibility of the system, said Kjellberg to manufacturingtalk.

The torch has dimensions reduced by 15%, which with a reduction of weight and enhanced performance capacities, this plasma-arc torch is the latest swirl-gas design.
A new plasma-arc automatic head change unit, the BWE, is a turret system for profile cutting machines.

By integrating now the ignition boxes for the HiFocus 130 and HiFocus 160i into the plasmatorch connection unit PBA-160 the units will be more compact.

In addition to the increase of ignition reliability the investment costs will be reduced.

This logical step was taken after the successful experiences with the more powerful HiFocus units, which were furnished before with similar combined plasmatorch connection units.

As a novelty for the consumable system, YellowXLife the Cathode T012Y is now available.

Constructed for oxygen cutting Kjellberg Finsterwalde offers a cathode which is suitable up to 360A cutting current.

YellowXLife offers a significant extended life time for nozzles and cathodes.

* Arc welding - welding tractors of the KA-series are the basis for various customised automatic welding systems.

They will be shown first time with a cross-slide for positioning the welding head.

This ensures high stiffness for rugged industrial applications.

A special column and boom device for welding longitudinal and circumferential seams on, for example, wind towers, tanks and tubes, will be exhibited.

It features 3-axis drive and adapters for various welding heads, including power sources, to ensure highest flexibility and productivity.

* Strip cladding - the range of equipment for the high performance welding technologies will be enlarged by strip cladding.

Especially for the submerged-arc welding and the electro-slag welding, the highest melting down rates and enormous cost reductions can be obtained, said Kjellberg.

* Kjellberg Finsterwalde at EuroBLECH 2008, Hannover, Germany, October 21-25, Hall 13, Stand D40.

Plasma Cutting System features heavy-duty welded steel frame

2008-08-15T19:24:00.000-07:00

Featuring uniframe design, tru-kut heavy-duty 5 x 10 ft system offers single set-up machining of frame and mounting surfaces. It utilizes Edge Ti CNC which includes touchscreen graphics display, on-board true shape nesting, and remote diagnostics/help capability. Air down draft cutting table includes 3 clean out doors on each side and parts catcher collects smaller parts falling through cutting slats. It also has digitally controlled brushless servo motors and high-precision motion system.

AKS Cutting systems introduces the new tru-kut heavy-duty 5' x 10' plasma cutting system. The rigid heavy-duty fully welded steel frame provides a stable platform for high precision plasma cutting.

Single set-up machining of the frame and mounting surfaces builds accuracy into the system and the heavy-duty design withstands rigorous usage requirements. The uni-frame design provides a compact footprint and allows for quick installation without any special floor preparation.

AKS tru-kut utilizes the easy to learn and use Edge Ti CNC which is specifically designed for plasma cutting applications and includes touch screen graphics display, on board true shape nesting and remote diagnostics/help capability and many more plasma application specific features.

Air down draft cutting table includes three clean out doors on each side for quick and efficient cleaning and a parts catcher to catch smaller parts falling through the cutting slats.

Latest technology digitally controlled brushless servo motors and high precision motion system with helical precision ground rack and pinions and linear guides provide quick acceleration, motion smoothness and accuracy.

http://findarticles.com/p/articles/mi_m0PIL/is_2008_May_7/ai_n25385978

Hypertherm simplified plasma cutting system

2008-02-12T06:42:00.004-08:00

Hypertherm has simplified mechanized plasma cutting system integration with the introduction of Hypertherm PowermaxEDGE. The 'bundled' solution integrates a patented Powermax G3 Series plasma system with either a standalone Sensor PHC, Plasma Height Control, or the EDGE Ti CNC with integrated torch height control.

Metal fabricators can configure the PowermaxEDGE for their specific requirements starting with one of three Powermax G3 plasma systems - the Powermax1000, Powermax1250 or Powermax1650 - depending on cutting requirements. Each model features patented Coaxial-assist technology as well as advanced torch and power supply designs to cut thicker plates, at faster speeds, with better overall cut quality and consumable life. The PowermaxEDGE with a Powermax1650 cuts up to 88" per minute on ½" thick plate.

Sensor PHC is an easy-to-use automatic plasma height control that maximizes cut quality. Designed for easy integration to CNC tables, it features simple operational controls and fault indicators. The PowermaxEDGE provides easy integration for small- to mid-range table applications, including original equipment manufacturers building light to medium gantry cutting tables, light duty cycle needs such as HVAC or custom fabricators, and for retrofit of existing oxy-fuel or plasma tables.

http://home.nestor.minsk.by/build/news/2007/04/2408.html

CAD/CAM supports ZUND cutting technologies

2008-02-12T06:42:00.003-08:00

An agreement between JETCAM International and ZUND Systemtechnik will ensure hat current and future ZUND cutting technologies are supported by JETCAM CAD/CAM productsCAD/CAM and Nesting specialists JETCAM International has announced an agreement with ZUND Systemtechnik, based in Switzerland whereby JETCAM Expert will be offered with the ZUND range of flatbed cutting machines. The agreement will ensure that current and future ZUND cutting technologies are supported by JETCAM products, with closer co-operation between sales, marketing, technical and development staff of both companies.
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.

'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.

Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.

JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.

* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.

In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.

* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.

For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.

http://www.manufacturingtalk.com/news/jea/jea165.html

Plasma cutting CNC runs Windows XP Embedded

2008-02-12T06:42:00.001-08:00

Hypertherm of Hanover, NH recently introduced a plasma cutting system with an optional CNC (computer numerical control) unit that runs Windows XP Embedded. The PowerEDGE system offers metal fabricators a "complete entry-level mechanized plasma cutting system with outstanding performance and value," the company claims.

Plasma cutting utilizes a high-velocity jet of ionized gas that flows from a constricted orifice. The gas, or plasma, conducts electricity from the torch of the cutter to the material to be cut, melting material and blowing it away. It is ideal for cutting steel and non-ferrous material (material without iron), less than one inch thick.

Hypertherm's PowermaxEDGE system comprises a Powermax G3 Series plasma system along with either a standalone Sensor PHC (plasma height control) unit or an EDGE Ti CNC unit. The latter unit provides integrated height control. It is that component of the PowermaxEDGE system -- the EDGE Ti CNC, when it is present -- that runs Windows XP Embedded.

The EDGE Ti CNC is used for shape-cutting control. It features, according to the company, a proprietary GUI (graphical user interface) and "SoftMotion Technology." The device includes a 15-inch touchscreen LCD and provides integrated servo control for up to four axes of motion.

The EDGE Ti CNC's embedded computer is based on an "industrial motherboard" equipped with a 1.2 GHz or higher Intel processor along with 512MB of DRAM. The device also provides at least a 60GB hard drive for control program and data storage, and includes two RS232 or RS422 serial ports, two USB 2.0 ports, and PS2 keyboard and mouse ports for connection of external peripherals.

The PowermaxEDGE system and EDGE Ti CNC are currently available. Pricing was not disclosed.

http://www.windowsfordevices.com/news/NS2818333901.html

CNC software targets plasma arc cutting equipment

2008-02-12T06:41:00.006-08:00

Designed for HyPerformance(TM) Plasma systems and FASTLaser(TM) processes, Automation CNC v6.0 provides HPR interface with full-screen diagnostics, configurable Watch Windows, and ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations. Along with facility for determining focal position, software offers Dynamic Pierce Control, auto process control, and laser marking capabilities.

Hanover, NH, USA - Automation CNC v6.0 software from Hypertherm, Inc. is now available for metal fabricators seeking greater productivity from mechanized HyPerformance(TM) Plasma systems and FASTLaser(TM) processes. CNC v6.0 is especially designed for applications of HyPerformance Plasma.

Newly released by Hypertherm Automation, CNC v6.0 is a performance upgrade that will be standard on all future shipments of Hypertherm CNC controllers including all EDGE[R], MicroEDGE(TM), Voyager(TM) and Mariner(TM) models. The company recommends that current CNC users contact their Hypertherm representative for specific information about system compatibility and available software upgrades to CNC v6.0.

The CNC v6.0 HPR (HyPerformance) interface is the most complete ever offered by Hypertherm Automation. It features full-screen diagnostics, configurable HPR Watch Windows, and the ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations by selecting material type, material thickness, process current and process gases.

The new CNC release also enhances FASTLaser software tools. Using Hypertherm's patent-pending process monitoring, it provides an automatic adjustment feature for determining focal position. The new automated focal position calibration routine simplifies the process of finding the spot where the laser focal position meets the material surface. It can be used whenever a shift in focal position occurs as with lens installation or resonator maintenance. Additional laser enhancements in CNC v6.0 include time saving Dynamic Pierce Control (DPC), auto process control and laser marking.

"Hypertherm is committed to being the supplier of choice for all our customers' thermal cutting needs," wrote Tate Picard of Hypertherm Automation in a recent Field Facts newsletter. "By actively soliciting feedback from our customers about software enhancements they'd like to see, we've been able to dramatically improve CNC v6.0 user interface screens and functionality. Additional requests from our customers promise to make CNC v7.0, already underway, even better."

Since 1968, Hypertherm has been the industry leader in plasma arc cutting equipment and service. Now, with its entry into the plate-laser cutting market, Hypertherm expands its technology leadership commitment. By continually delivering breakthrough advances in metal-cutting productivity and precision - first in plasma, now also in laser - Hypertherm reaffirms and extends its position as the world's leading supplier of advanced high temperature metal cutting technology. Hypertherm serves a wide range of industrial metal cutting needs from its headquarters in Hanover, New Hampshire, with subsidiaries, sales offices and partner representation worldwide.

Hypertherm, HyPerformance, FASTLaser, EDGE II, MicroEDGE, Voyager and Mariner are registered trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

http://www.cnc-info.blogspot.com/

CNC PLASMA CUTTING

2008-02-12T06:41:00.005-08:00

CNC (computer numerically controlled) plasma cutters fully automate the shape production process. Early cnc machines used a tape with small holes punched through to provide instructions to a primitive (by today's standards) computer.

Today's CNC units use either expensive limited production computers made specifically for running burning machines, or personal computers adapted to run the machines. While the latter group lack some of the refined features of the $100,000 and up machines, such as automatic shape nesting and automatic tip height control, they provide the same cut quality and production speed.

In CNC cutting, you arrange your shapes on the computer screen and cut them automatically, without having to touch the material.

CNC software lets you program pauses for piercing, scale up or down in seconds, set acceleration and deceleration at corners, and other functions not possible with electric eye units.

The above shapes were created in CorelDraw, and then turned and nested together to minimize scrap material. The group of shapes were then exported as a single DXF file. The file was then imported into our Torchmate driver software, which automatically converts it to G-code for cutting.

The shapes are cut in a sequence that minimizes the distance the torch must travel. While cutting speed here is 80 inches per minute (IPM), rapid traverse between cuts is 300 IPM.

http://www.plasma-cutter.com/cnc.htm

SELECTING A PLASMA CUTTER

2008-02-12T06:41:00.003-08:00

So you want to purchase a plasma cutter! It's kind of a bewildering prospect to select a piece of equipment that is new to you with so many manufacturers and models to choose from.

Let 's approach the problem logically. To start with, there are a number of questions that you must answer for yourself, before you can go any further:
How many hours a day do you plan to use your plasma cutter? In other words, what kind of duty cycle must it have?

What kind of electrical service do you have where you intend to use the machine? Is it 50 amp 220 volt single phase, or perhaps 30 amp 110 volt single phase? What other equipment will be running simultaneously on the same circuit?

What kind of portability must your plasma cutter have? Will you be using it exclusively in your shop, or will you need to take it to the job? Do you have a means of supplying the machine with compressed air in remote locations? How will you do that, with a portable compressor or an air bottle? How will you supply electric current at the site?

What kind of material do you plan to cut, and how thick is it likely to be?

Will you be doing manual cutting exclusively, or is there a possibility that you may want to use your plasma cutter with a CNC cutting machine?

What are your budget limitations?

Generally speaking, the higher the amperage output of the plasma cutter, the greater the duty cycle is at lesser amperages. In other words, if you plan to use the machine around the clock, you should consider a larger unit than you would need to cut the material you will be working.

If you will be using your machine frequently, but not continuously, consider a unit that is capable of cutting the thickest material you are likely to work. Most manufacturers provide duty cycle information in their literature.

Many people make the mistake of thinking that the greater the capacity of the machine, the better it is. In general, fabricators consider oxy-fuel to be superior to plasma for cutting steel when thicknesses exceed about 1/2 inch. This is because of the slight bevel (4 to 6 degrees) in the cut face that plasma produces. It is not noticeable in thinner materials, but becomes more so as thicknesses increase. Also, at thicknesses above 1/2 inch, plasma has no cutting speed advantage over oxy-fuel.

There is little point in buying a plasma cutter that will cut 1 1/2" plate, if you are going to use acetylene for such work anyway. If you are planning to cut non-ferrous metals such as stainless or aluminum, which cannot be cut by oxy-fuel, consider a 50 to 80 amp. 220 volt plasma cutter.

If you plan to use your plasma cutter outside the shop occasionally, you should consider one of the new breed of semi-portable machines. These units are little powerhouses that weigh less than 100 lbs., yet are capable of cutting 3/4" to 1" in a pinch. You will need a bottle of air or a compressor, and a hefty portable generator.

If you believe that you may automate your plasma cutting at some point, you must select a unit that does not use a high-frequency starting circuit. A high-frequency start acts like a spark plug in a car. Rather than using a relatively lower voltage pilot arc to initiate the plasma process, it uses a high voltage spark. This causes electrical interference such as locking up the computer, destroying files, etc. None of Hypertherm's Powermax units use a high frequency starting circuit.

Like most other things in life, you get what you pay for. Imported plasma cutters can be found on the market for $800 or less. However, that is money that could be put toward a modern inverter type unit costing more initially, but less over time when the cost of replacement parts and consumables is factored in. On that note, it should be pointed out that Hypertherm's Powermax line uses a new, patented air flow system and torch design that actually delivers up to 4 times the consumables life of their other models and competing brands.

Make your selection intelligently, based on the above considerations, and your plasma cutter will give you years of reliable performance. Don't make the mistake of purchasing a unit on the basis of cost. An inexpensive machine that doesn't meet your needs is no bargain.

http://www.plasma-cutter.com/selection.htm

HOW A PLASMA CUTTER WORKS

2008-02-12T06:41:00.001-08:00

Plasma cutters work by sending an electric arc through a gas that is passing through a constricted opening. The gas can be shop air, nitrogen, argon, oxygen. etc.

This elevates the temperature of the gas to the point that it enters a 4th state of matter. We all are familiar with the first three: i.e., solid, liquid, and gas. Scientists call this additional state plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to the work.

The restricted opening (nozzle) the gas passes through causes it to sqeeze by at a high speed, like air passing through a venturi in a carburetor. This high speed gas cuts through the molten metal. The gas is also directed around the perimeter of the cutting area to shield the cut.

In many of today's better plasma cutters, a pilot arc between the electrode and nozzle is used to ionize the gas and initially generate the plasma prior to the arc transfer.

Other methods that have been used are touching the torch tip to the work to create a spark, and the use of a high-frequency starting circuit (like a spark plug). Neither of these latter two methods is compatible with CNC (automated) cutting.

The photo at right shows consumables from a Hypertherm Powermax 900 plasma cutter. The electrode is at the center, and the nozzle just below it. The orange piece above the electrode is the swirl ring, which causes the plasma to turn rapidly as it passes.

While these parts are all referred to as consumables, it is the electrode and nozzle that wear and require periodic replacement.

http://www.plasma-cutter.com/technical.htm

Plasma cutters are ideal for accuracy

2008-02-12T06:40:00.003-08:00

Plasma cutters are one of the most modern tools for cutting all kinds of metal. A plasma cutter uses electricity to superheat gas to the point where it becomes plasma, which can then be used to cut metal. Because there is no friction between surfaces produced by this process the resulting material will be free of burrs and imperfections. When you combine this technology with CNC (computer numerically controlled) machinery you have a cutting tool that can produce incredibly accurate and detailed patterns even in thick steel and titanium.

Plasma technology

CNC plasma cutting machines use computer programming and precise robotic controls to automate the production of shapes and patterns in metal. With a CNC plasma cutting tool you can produce precisely proportioned metal pieces with a minimum of burrs and imperfections. The accuracy and precision of CNC plasma cutting means that components can often be taken directly from the cutting machine and put into use without further finishing, saving time, effort, and expense.

Principles of operation for a CNC plasma cutter

As mentioned, a CNC plasma cutter uses computer programming to direct the plasma onto the material. This plasma is produced by feeding a gas past an electrode, which superheats this gas (gases used include oxygen, argon, and nitrogen) until it becomes plasma.

Plasma is a fourth state of matter (in addition to solid, liquid, and gas) and this plasma is directed through a restricted opening onto the surface of the metal. Once the plasma contacts the metal the metal is cut using heat. Because the metal is superheated to a molten state there is no messy residue left behind as there is when using friction-based cutting systems (saws).

A CNC plasma table

The best way to direct your plasma cuts is with a CNC plasma table equipped with a gantry that moves the CNC plasma cutter above the work to be cut. Because a CNC plasma cutter is so hot, however, a CNC plasma table does not actually have a table surface. Instead, the metal you are cutting becomes the table surface, and the cut pieces fall through to a holding area beneath the machine. The accuracy and technical sophistication of CNC plasma cutting are the main reasons why many companies that work with metal have switched to plasma cutters.

http://www.insidewoodworking.com/cnc/plasma_cutters.html

Plasma-arc CNC profilers offer high accuracy

2008-02-12T06:40:00.001-08:00

Esab Automation now has an extended range of Eagle portal cutting machines which have been designed for precision plasma cutting. There are four models in the range which combine high productivity with high accuracy. Advanced process integration ensures consistently high levels of cutting quality.

The four EAGLE machines offer cutting widths from 1500mm, with one torch, up to 3000mm with two torches.

Cutting thickness is up to 30mm with cutting speeds and positioning rates up to 35mm/minute.

The Eagle’s feature automatic switching from cutting to marking.

To promote the highest plasma cutting quality, a number of advanced design features are included.

The voltage related electric arc height regulation ensures optimum cutting quality through the entire cutting process.

The machine’s double side synchronised rack and pinion drive together with an advanced guiding system ensure 100% accuracy over the entire cutting range.

The cutting torch height is exactly pre-set by the Super Rapid Initial Height Sensing System which positions the plasma torch precisely in less than 1.5 seconds, thereby also eliminating unnecessary down time.

Economy, efficiency and flexibility are hallmarks of Esab precision plasma systems they provide exact cutting edges with little slag, minimum material deformation due to a very restricted heat affected zone and no reworking.

By configuring the plasma systems, plate thicknesses up to 30mm can be cut in stainless steel, aluminium or unalloyed steels.

Accompanying the Eagle range are Esab Vision Control Systems.

These provide comprehensive control possibilities with integrated cutting databases and the possibility of implementing fully automated production cycles.

Full details of the entire Eagle range are provided in new literature available from the company - telephone Esab for details.

http://www.cncmachinesinfo.com/articles/

Making plasma cutting easier Using CNC automation technology

2008-02-12T06:38:00.000-08:00

For many people, the world of plasma cutting is a complex and daunting place, with a cryptic set of rules that can be mastered only by highly trained technicians after weeks of training. For every change of material or thickness being cut, a long process ensues of resetting gas mixtures, tweaking pierce heights and pierce delays, and manually calibrating every last parameter to ensure a reliable result.

For many people, the world of plasma cutting is a complex and daunting place, with a cryptic set of rules that can be mastered only by highly trained technicians after weeks of training. For every change of material or thickness being cut, a long process ensues of resetting gas mixtures, tweaking pierce heights and pierce delays, and manually calibrating every last parameter to ensure a reliable result.

However, technological advancements have automated the calibration process and eliminated the guesswork to make highly precise plasma cutting accessible to large and small fabrication shops alike. By working together to develop their technologies, CNC machinery companies and plasma unit manufacturers have optimized machinery control systems to take full advantage of the speed and power of plasma cutting. CNC technology allows systems to communicate to maintain unprecedented levels of control over the quality of plasma cuts.

This level of control is achieved by linking all parameters of a plasma unit to the same CNC unit that instructs the motion of the head, which allows the controller to compute all factors that might affect the quality of a cut. Anytime the material type, thickness, or plasma process is changed, several parameters must be adjusted, such as feed rate, pierce delay, pierce height, and gas mixture. Instead of adjusting dials and making precise measurements before running a job, the operator simply loads the material to be cut and then selects the material type from a menu-driven list on the machine keypad. The controller then automatically configures the machine and the plasma unit. This greatly reduces setup time and nearly eliminates the margin for human error, naturally improving job efficiency, production time, and job quality.

From the User’s Angle

Normally, a user creates a nested sheet of parts in a CAD/CAM system and then saves the machine-ready file on a computer or network server. New systems can have a built-in Ethernet connection and communicate via DNC using standard TCP/IP to the user’s computer or to a network server. At the machine, the user loads the material and selects the material type. The controller prompts the user to insert the appropriate torch consumables.

The user then selects the job and starts the cutting. When equipped with a bar code scanner, the computer can produce a printed work order for all jobs to be cut, allowing the operator to commence jobs simply by scanning the appropriate code on the sheet, prompting the job file to be loaded and executed automatically.

The Cutting Process

The process of cutting with plasma involves an electrical reaction, so unlike other cutting techniques, plasma cutters can cut only materials that conduct electricity. When a job file is started, the machine moves to the first pierce or cut position and the torch moves down toward the material. On the end of the torch is a device called an ohmic sensor. Once the ohmic sensor makes contact with the surface of the material, it closes an electrical circuit, informing the machine that it has reached the surface of the material. The torch then lifts above the material to the pierce height. The pierce height is higher than the cutting height to prevent hot metal from shooting directly back into the torch during the pierce process.

Once the pierce is complete, the torch moves to the cut height and begins to cut. The optimum pierce height, cut height, and feed rate all are based on the consumables and the material being cut. On sophisticated plasma cutting systems, all of these parameters are set automatically.

Once the cutting begins, the distance between the torch and the top of the material is maintained by reading the voltage from the plasma arc, in a process known as automatic torch height control (ATHC). Generally, sheets of material do not lie completely flat, especially thin-gauge material. To ensure a high-quality cut, it is important to maintain a constant distance between the torch and the material surface. Maintaining a constant height requires a responsive ATHC system. On some systems, the arc voltage is checked at a rate of 500 times per second, and the readings are used to adjust the Z axis up or down accordingly. The result is a quality cut that does not require user intervention.

Improvements and Advancements

The process described seems simple, but actually it is a result of extensive developments in modern technology. Older plasma systems, as well as many modern ones, do not take advantage of these new developments and require painstaking manual adjustments to produce parts that remain inferior in edge quality and efficiency. As further technological developments are made, the quality gap between less advanced systems and modern ones is widening at a fast pace.

One of the latest advancements in plasma cutting technology is 200-amp fine plasma cutting. This process produces a more constricted plasma jet for a higher arc density and more accurate cutting. The result is a smooth, precise cut that is almost dross-free.

The condition of the plate with regard to rust or reflectivity does not affect the cutting process. A high-quality fine plasma cutting system allows the cutting of holes with diameters nearly equivalent to the thickness of the material being cut. For example, good-quality 0.35-in.-diameter holes can be cut accurately in 0.25-in.-thick material.

Moving Forward

Many companies today are committed to moving this technology forward. In the future, leading companies will continue to work closely together to push the technological envelope, making plasma technology faster, more accurate, and easier to use.

http://www.thefabricator.com/PlasmaCutting/PlasmaCutting_Article.cfm?ID=675

Plasma-arc CNC profilers offer high accuracy

2007-12-18T23:12:00.002-08:00

Portal cutting machines have been designed for precision plasma-arc cutting, combine high productivity with high accuracy and their advanced process integration ensures high levels of cutting quality.

Esab Automation now has an extended range of Eagle portal cutting machines which have been designed for precision plasma cutting. There are four models in the range which combine high productivity with high accuracy. Advanced process integration ensures consistently high levels of cutting quality.

The four EAGLE machines offer cutting widths from 1500mm, with one torch, up to 3000mm with two torches.

Cutting thickness is up to 30mm with cutting speeds and positioning rates up to 35mm/minute.

The Eagle’s feature automatic switching from cutting to marking.

To promote the highest plasma cutting quality, a number of advanced design features are included.

The voltage related electric arc height regulation ensures optimum cutting quality through the entire cutting process.

The machine’s double side synchronised rack and pinion drive together with an advanced guiding system ensure 100% accuracy over the entire cutting range.

The cutting torch height is exactly pre-set by the Super Rapid Initial Height Sensing System which positions the plasma torch precisely in less than 1.5 seconds, thereby also eliminating unnecessary down time.

Economy, efficiency and flexibility are hallmarks of Esab precision plasma systems they provide exact cutting edges with little slag, minimum material deformation due to a very restricted heat affected zone and no reworking.

By configuring the plasma systems, plate thicknesses up to 30mm can be cut in stainless steel, aluminium or unalloyed steels.

Accompanying the Eagle range are Esab Vision Control Systems.

These provide comprehensive control possibilities with integrated cutting databases and the possibility of implementing fully automated production cycles.

Full details of the entire Eagle range are provided in new literature available from the company - telephone Esab for details.

http://www.cncmachinesinfo.com/articles/

Plasma cutters are ideal for accuracy

2007-12-18T23:12:00.001-08:00

HOW A PLASMA CUTTER WORKS

2007-12-18T23:11:00.001-08:00

SELECTING A PLASMA CUTTER

2007-12-18T23:10:00.000-08:00

CNC PLASMA CUTTING

2007-12-18T23:09:00.002-08:00

CNC (computer numerically controlled) plasma cutters fully automate the shape production process. Early cnc machines used a tape with small holes punched through to provide instructions to a primitive (by today's standards) computer.

Today's CNC units use either expensive limited production computers made specifically for running burning machines, or personal computers adapted to run the machines. While the latter group lack some of the refined features of the $100,000 and up machines, such as automatic shape nesting and automatic tip height control, they provide the same cut quality and production speed.

In CNC cutting, you arrange your shapes on the computer screen and cut them automatically, without having to touch the material.

tm2_action_sm.jpg (11620 bytes)

CNC software lets you program pauses for piercing, scale up or down in seconds, set acceleration and deceleration at corners, and other functions not possible with electric eye units.

The above shapes were created in CorelDraw, and then turned and nested together to minimize scrap material. The group of shapes were then exported as a single DXF file. The file was then imported into our Torchmate driver software, which automatically converts it to G-code for cutting.

The shapes are cut in a sequence that minimizes the distance the torch must travel. While cutting speed here is 80 inches per minute (IPM), rapid traverse between cuts is 300 IPM.

http://www.plasma-cutter.com/cnc.htm

CNC software targets plasma arc cutting equipment

2007-12-18T23:09:00.001-08:00

Plasma cutting CNC runs Windows XP Embedded

2007-12-18T23:08:00.000-08:00

agreement between JETCAM International and ZUND Systemtechnik will ensure hat current and future ZUND cutting technologies are supported by JETCAM CAD/CAM productsCAD/CAM and Nesting specialists JETCAM International has announced an agreement with ZUND Systemtechnik, based in Switzerland whereby JETCAM Expert will be offered with the ZUND range of flatbed cutting machines. The agreement will ensure that current and future ZUND cutting technologies are supported by JETCAM products, with closer co-operation between sales, marketing, technical and development staff of both companies.
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.

'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.

Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.

JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.

* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.

In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.

* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.

For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.

http://www.manufacturingtalk.com/news/jea/jea165.html

CAD/CAM supports ZUND cutting technologies

2007-12-18T23:07:00.000-08:00

Hypertherm simplified plasma cutting system

2007-12-18T23:06:00.001-08:00

Software for cutting machines - Systems and Software

2007-12-18T23:02:00.001-08:00

Columbus software, an integrated package designed specifically for cutting machines, is said to offer simple setup and full process control for every cutting machine in a shop, plus part programming, true shape nesting, common line cutting, plate and inventory management, parts management, and machine-specific estimating in a single integrated package. Modules can run on a desktop workstation, or the basic package (Vision Plus-CNC) can run directly on the company’s Vision PC or NT control. In addition, the software will support other cutting systems.

The software supports straight or bevel cutting with oxyfuel, plasma, waterjet and laser, plus all current marking devices, in numerous combinations.

An estimating module tracks specific information, such as the machine’s cutting speeds, rapid speeds, lift speeds and pierce times for accurate job costing. This information can be exported to Excel or other databases for customized reporting and costing.

http://www.findarticles.com

CNC plasma cutters available from machineryequipment website

2007-12-18T23:01:00.002-08:00

The new and bright way to buy and sell CNC plasma cutters online is the machineryequipment website.

CNC plasma cutters

Whether it is a new CNC plasma cutter or a second hand plasma machine that a company has out grown; machineryequipment is the website to see, it has all the top brands and the new Plasma cutting technology. The website does not sell the products direct; it advertises all the good deals around Australia.

The beauty of the machineryequipment website is that the user is in control of advertising the product, the negation of purchasing is as simple as finding the product that one wants and contacting the supplier.

http://www.ferret.com.au/articles/z1/view.asp?id=2813

Plasma cutting system

2007-12-18T23:01:00.001-08:00

HYPERTHERM, represented in Australia by Westgate Hi-Tech Machinery, will exhibit the HyPerformance HPR260 plasma cutting system at the 2005 Schweissen & Schneiden Welding and Engineering Show in Essen, Germany.

By enhancing HyDefinition technology, HyPerformance boosts performance, productivity and profitability with consistent cut quality across a full range of plate thicknesses. It is suitable for cutting fine feature parts, a capability that will be demonstrated at the stand.

Powermax live cutting will take place at Stand 322, including both handheld and mechanised demonstrations. Hypertherm’s laser-plate cutting technologies will also be featured with a focus on the LH1575 FASTLaser cutting head. All mechanised demos will incorporate Hypertherm Automation’s EDGE II fast, accurate CNC controller.

Hypertherm consumables will be on display, highlighting performance-enhancing SilverPlus, FineCut and HySpeed technologies, as well as Hypertherm’s RT60 and RT80 retrofit torches, which deliver performance similar to newer Powermax G3 systems when retrofitted to older models. Centricut consumables will also be represented.

http://www.ferret.com.au/articles/cf/0c0318cf.asp

CNC profile plasma tables

2007-12-18T22:59:00.001-08:00

ADVANCED Robotic Technology (ART) CNC profile plasma tables, including the SVP series 4400, will be demonstrated at Austech 2004 during National Manufacturing Week in Sydney from June 1-4.

ART has developed a machine which keeps in total control either by using the touch-screen and/or pendant control.

This makes it easy to learn, providing on-the-fly operational information, while the interactive touch-screen provides a quick and simple means of entering machine instructions.

Profile Master, the software which achieves absolute productivity with Windows-based integral CAD/CAM profiling, packed with real-world features, and Powermax G3 series from Hypertherm, the performance standard for air plasma cutting technology, will also be displayed at the Austech 2004 show.

The smart plasma range is also able to handle the highs and lows by maximising consumable life, performance, as well as integrated tool control systems - the intelligent torch height controller, the initial height sensor and the break-away torch protection mechanism, which are standard on all machines.

All SVP plasma machines include a weaved deck and downdraft extraction trough which travels along with the gantry to reduce emissions into the work area, which ultimately keeps scrap collection and cleaning to a minimum.

Manufacturers don't have to go overseas for a quality plasma cutter, ART has everything right here -- industrial strength, outstanding quality, exceptional value, and innovative software.

ART also manufactures the most advanced range of CNC routing tables from three metres through to 14 metres.

http://www.ferret.com.au/articles/1e/0c01f01e.asp

Budget profile plasma cutter

2007-12-18T22:58:00.002-08:00

ADVANCED Robotic Technology (ART) will display its new CNC SMART profile plasma cutter on Stand 1100 during the 2006 Queensland Manufacturing Technology Exhibition (QMan), at the Brisbane Convention & Exhibition Centre, from October 17-19.

SMART standard features include:

* Touch-screen control.

* Profile shop SMART software.

* Automatic pierce height control.

* Mechanical torch height control.

* Smooth motion control.

* Servo motor drive.

* Traverse speed of 24+ m/min.

* Linear bearings.

* Powder coated chassis and gantry.

Also displayed will be ART's range of CNC profile plasma and routing machinery, Hypertherm plasma units, Keenedge tooling, Colombo spindles, and profiling/optimising software such as ProfileMaster and EnRoute.

ART machines are all designed and manufactured in Australia for supply to aluminium and plastic engineers, boat builders, cabinet makers, metal fabricators, and other industries.

CNC plasma-arc profilers raise capacity

2007-12-18T22:58:00.001-08:00

Three CNC cutting and profiling systems, using advanced plasma-arc cutting and precision guidance systems, produce ultra-precise blanks, usable without time-consuming manual reworking

Three CNC plasma-arc cutting machines from ESAB Cutting Systems have increased production capacity at a major manufacturer of aluminium and steel dumper truck bodies. Every month the company processes, an average of 420 tonnes of steel sheet and plate, with thicknesses ranging from 3 to 25mm as well as 30 tonnes of aluminium up to a thickness of 30mm.

The plasma-arc cutting process is used for cutting steel and aluminium.

The first ESAB Suprarex plasma-arc cutting machine has a working range of 12m x 3m.

The latest one has even a larger working range, of 24m x 3m.
Each machine features two high-precision plasma-arc torches and a fume extraction table with a highly efficient fine dust filtering system.

The cutting machines are fully integrated in the production process.

In view of the large number- some 4500 - and complexity of the different parts, manual production is impossible.

Cutting is the first step of the production process and all cutting operations on the Suprarex machines are controlled automatically at a central station.

The cutting parameters are set up using ESAB's COLUMBUS programming software.

The cutting data for each individual part is stored and can immediately be transmitted to the corresponding machine via the network.

The automatic nesting facility is particularly efficient and time-saving - individual cutting paths are designed so that material loss is kept to a minimum.

After cutting, the cut blanks are formed in four tandem bending presses and then robotically assembled and painted.

The advanced plasma-arc technology, in combination with ESAB's precision guiding machines, allows ultra-precise parts to be produced without time-consuming manual reworking.

The costs of investment in the plasma-arc plant is also much lower when compared with laser cutting system prices, said ESAB.

The Suprarex cutting systems significantly contribute to making the whole production process more effective and efficient.

Automatic creation of the nesting schedules reduces the work preparation requirements and set-up times are very short when it comes to cutting a different part.

http://www.manufacturingtalk.com/news/eab/eab145.html

Plasma Cutting Boosts Armor Production

2007-12-18T22:57:00.000-08:00

O'Gara-Hess & Eisenhardt (OHE; Cincinnati, OH) first made a name for itself in 1948, when it engineered a bullet-resistant limousine for US President Harry S. Truman. Since then, more than 60 international heads of state and a long list of diplomats have been customers. Part of the Mobile Security Division of Armor Holdings Inc., the company today is the world's largest provider of wheeled vehicle armor.

The armor plate OHE installs ranges from 1/4 to 3/4'' (6.4-19-mm) thick. Because the company retrofits armor to existing vehicles, pieces must sometimes be cut to fit into very tight places with tolerances in the range of ±0.015'' (0.38mm).

Keith Kilpatrick, director of manufacturing engineering at OHE's Fairfield, OH, plant, needed to boost cutting capacity to support the company's increasing business. He had his eye on a plasma cutting system he had seen in a sister plant in Germany, and contacted a representative of ESAB Cutting Systems (Florence, SC).

Developed by a team of US and German engineers, ESAB's Acer 2 plasma cutting system featured highspeed dual side drives, a precision linear rail cross axis guidance system, the company's Precision Plasmarc plasma system, and a Windows-based CNC. It can provide good cut quality on carbon steel, aluminum, and stainless steel

Precision Plasmarc is a proprietary arc constriction technology that results in very low cut edge bevel angle and minimal dross, and requires little or no clean-up. It allows cutting and plasma marking with the same torch when used with an optional integrated flow control and PC. This eliminates the need for a dedicated marking station, improves accuracy by eliminating the need for tool offsets, and speeds cycles by cutting out machine motion between offsets.

The Fairfield facility has grown into two separate production buildings, both using a cellular assembly line process to produce military and commercial vehicles. In both cases, the vehicles are first disassembled and gutted, then the armor package is applied and the vehicles are reassembled.

Armor packages include ballisticgrade steels welded throughout the passenger compartment, transparent armor consisting of multi-layered ballistic glass, battery protection to ensure continued power supply, and Runflat wheels to help the vehicle reach safety in the event of an attack. Suspension upgrades are also included if required.

The machine's integrated flow control uses CNC-controlled proportional valves to control cut, start, and shield gases. Process parameters are selected and stored in the control, but can be manually adjusted and saved for future use, giving the operator flexibility.

Installed in November 2003, the initial Acer machine was so successful a second unit was added in June 2004. The machines have been instrumental in meeting OHE's demanding production schedules, including 350 Up-Armored Humvees per month for the US Army.

http://findarticles.com/p/articles/mi_qa3618/is_200505/ai_n13637771

Affordable CNC Plasma Cutting Machine

2007-12-18T22:56:00.000-08:00

The plasma cutting process uses high velocity as well as high temperature ionized gas along with an arc, to cut different types of materials.

Plasma cutting process

The plasma cutter torch has a high velocity ionized gas that conducts electricity, which is used to heat the work piece and eventually melts the material. While the purpose of the arc is to melt the material with its high heat, the function of the gas is to blow the molten material away from the piece and cut the material. Due to the force of the plasma, you get a clean cut with very little or no slag at all. The plasma arc roughly has a speed of up to 20,000 feet per second (that’s more than 13,000 miles per hour!) while the temperature is as high as 30,000º F.

Different types of Plasma cutting machines

Plasma cutting machines are available in a variety of types such as plasma torches, plasma torches, and plasma cutters. Compressed air or nitrogen is used as a cutting gas in plasma cutting torches. The torches have a narrow-width kerf along with a water-cooled electrode. Plasma torches use a high temperature gas steam, which is produced by passing the gas through an electric arc discharge. The plasma torch has two electrodes that are metallic and tubular in nature. The electrical arc flows between the negative or positive electrodes. Plasma cutters are specially used for cutting steel and materials that conduct electricity.

Advantages of Plasma cutting machines

* They provide high quality cuts and fast travel speeds.
* It is a low cost process for short runs as no physical tooling is required.
* A cost effective option for thick metal sheets.
* As compared to laser cutting can cut thicker sheets.
* It can be used to cut a wide variety of geometric shapes along with 2D shapes that do not require too much precision.

Specifications

The process can be used on ferrous and non-ferrous metals and requires only software tooling. It helps to reduce cost by reducing total cut length. At times, some warping may occur on complex parts. The cut edge is somewhat roughened and may show the presence of an oxide layer. Further, the plasma cut surface may not be precisely perpendicular to the surface of sheet material.

http://www.emachineshop.com/articles/affordable-CNC-plasma-cutting-machine.htm

Plasma Cutting Machine has rigid, space-conscious design

2007-12-18T22:55:00.002-08:00

Offered with multiple plasma torch options, EdgeMax features unitizedPlasma Cutting Machine has rigid, space-conscious design. steel table/frame, full capture bearing assemblies, and low-mass aluminum beam driven by dual brushless ac motors. Global S CNC control with Windows® OS, also included, facilitates machine operation for any level of operator. The basic models available are H, for HVAC, blowpipe, and OEM shops; G, for general fabrication shops; and P, for precision plasma cutting.

http://news.thomasnet.com/fullstory/535807

Everything you need to know before you purchase a CNC plasma cutting machine

2007-12-18T22:55:00.001-08:00

CNC plasma cutting machines are more affordable and easier to operate than ever before. By knowing the right kind of hardware and software makes sense, a fabricator can choose the equipment that makes the most sense for his operation.

The process of choosing a CNC plasma cutting system is much more difficult today than it was 10 years ago, when systems were fewer but more expensive. By 2000 several progressive manufacturers had developed low-cost CNC plasma cutting systems that could run off of a PC.

Hardware and software developers made huge contributions with new, affordable, easy-to-use products. By 2004 it was becoming a chore for the first-time buyer to sort out the increasingly wide range of prices and new models on the market. Knowing about the different CNC plasma cutters available to you and what they are suited for will help you make the best investment for your capabilities.

First, you have to organize the market choices into three categories. One of these categories will have the right CNC plasma cutter for you. These categories, which are organized by price, do not necessarily indicate the level of quality and performance each provides. The price for each group is based on systems with a 5- by 10-foot or smaller cutting surface.

The first group comprises CNC plasma cutting systems that cost $25,000 or less, which have contributed greatly to the profitability of the small shops. They are available as complete plug-and-play systems or as kits. When you get a system from this category, it is important to use it for its intended purpose, which generally is light-duty industrial and artisan applications.

The second category of plasma cutting machines includes units that are priced at $60,000 or less. Some would argue that this group of machines includes the best of both worlds. Like the machines in the first group, they can give a lot of bang for the buck. They are engineered to perform well in demanding applications, up to and including the midindustrial market.

The best systems in this group are built to work hard; even the small tables can weigh up to a ton. They are capable of running one to two full shifts per day continuously with little maintenance. Some come with excellent industrial-grade software, hardware, and drives. Small shops with up to about 20 employees are the largest consumers of the machines from this category, which can handle anything from HVAC-gauge material to thick plate. Machines in this group usually are backed by good customer support, including live, on-screen assistance. This category is a good place for the growing business to start.

The third category includes large, feature-rich, multihead systems with price tags of between $60,000 and $200,000 or higher. These units, which have plenty of features and are smooth, accurate, and easy to operate, are at home in high-production shops. They also come with excellent customer support options. While the biggest and best are in this group, there are some pitfalls as well. Even in these high-end machines, some of their technology is outdated.

Every CNC plasma cutting machine is made up of three independent systems. Let's explore them further.
Mechanical Systems

The mechanical system on a plasma cutting machine includes the drive, the gantry with a torch height mechanism, and the cutting table. These components are not easily upgraded, so it is important to choose them wisely.

Rack-and-pinion gear drives are the most common. The rack gear runs the full length of each axis and the spur gear travels along it. Both are subject to high wear from metallic plasma dust. High-quality machines have a spring-loaded pinion gear to keep it running tight against the rack gear, otherwise the drives will develop play and backlash through use.

Some designers in the industry are advocates of using geared-timing belt drives because they cost less than rack-and-pinion gear drives, have zero backlash, and have long life. Because no force develops between the tool (torch) and the material, and the plasma cutting environment is so dirty, industrial geared-timing belts may be a good choice.

Sometimes a gear-reduction transmission can develop a bit of backlash. A little play in the transmission is not a deal breaker. It may transmit less than 0.001 inch of play at the torch. Also, most controllers can be set to compensate for a little backlash.

The drives should be enclosed or protected in some way. They should not be too exposed to the plasma dust and debris. Also, the drives shouldn't be vulnerable to getting hit by a falling piece of plate or an errant forklift. Basically, you are looking for maintenance-free operation.

Plasma cutting is all about time and accuracy, and the two most significant factors in saving time are material handling and software. You might think that cutting speed is a major factor. Yes, you can save seconds and minutes by tweaking your feed rate, but you can save hours in a week with good software and good material handling procedures.

For good material handling practices, the table should be easy to load and off-load. The gantry should be parked off of the cutting surface, so that a forklift can come straight in when loading heavy plate. The table should be able to handle a full sheet with no built-in obstructions. Also, most operators want the grates to be flush or a bit higher than the frame, which makes it easier to off-load heavy parts.

The cutting table must be able to handle a lot of weight, even if you are not planning to cut heavy plate. If you need to cut plate that is too thick for your plasma power supply, you can slide the plasma torch out of the housing and slide in an oxyfuel torch (they are all interchangeable). Now you are able to cut 2- to 4-in. material, and if you bought the right system, the controller will interface with on/off solenoids on the oxyfuel torch.

Check for play and flex by wiggling the gantry and automatic torch height control mechanism in several places while the machine is stationary. Look to see that the linear rails are secured along their full length. Be sure to run the machine through a few tests at different speeds with the plasma cutter turned off. Watch and listen. Everything should be snug and run smoothly and quietly. Stepper motors, as opposed to servomotors, make a buzzing sound that has nothing to do with the mechanical elements of the system.

Automatic torch height controls (ATHC) can be problematic. A good-quality control can be expensive, so it is important to give it a good workout, especially if you are looking at a lower-priced machine. An adjustable pierce height will significantly increase the consumable life and enable you to pierce and cut much thicker material. Also, make sure the ATHC does not have any sensors or wires sticking out that can get damaged.

The linear guide wheels on each axis are keys to ensuring smooth and accurate motion control. V-groove wheels with sealed bearings are desirable, and they should be spaced widely for increased stability. Cam followers are rightly used sometimes in group 1, but not often in groups 2 or 3.

CNC plasma cutting creates smoke that contains unhealthy black metallic dust as well as ozone. Smoke extraction systems usually come with the machines in group 2 and 3, in the form of a waterbed or a plenum/fan setup. Waterbeds have the added benefit of cooling the material during cutting. Both systems will extract smoke if they are set up correctly.
Hardware

Hardware comprised of the electronic system that controls the transmission (belt or gears) that moves the torch. Of course, this system must operate without a glitch and be maintenance-free. The computer and controller, cables, motor, and any remote control device work together to make the plasma torch do exactly what you have specified in the software program.

Overall, a closed-loop servo system is better than an open-looped stepper. Like the mechanical components, the hardware is not easily upgraded.

Some controllers cannot be upgraded with the latest CAD/CAM software. CNC software is improving in performance and price, and you will want to be able to upgrade as your business grows. Don't get stuck with a machine that can't be upgraded.
Software

There are actually three different software programs in your plasma cutting system: CAD, CAM, and controller.

CAD software is used to draw the parts. If you are a heavyweight with computers, you may be accustomed to AutoCAD®. Other programs available include AutoSketch® and CorelDRAW®. If you don't have any CAD experience, don't worry about it. It is getting easier and easier to learn. And that's what customer support is for. You can be drawing simple parts in an hour.

Sometimes your customer will e-mail you a nice drawing saved in a DXF file format, but sometimes a customer will shuffle into your shop, butt out his smoke, and make a sketch on your floor with a piece of soapstone. You will really be able to dazzle the old boy when you step up to your monitor and redraw his floor art in the form of a perfect CAD drawing. Remember to save your masterpiece as a DXF file.

CAM software is used to make the CAD drawing ready for cutting. It is important to make sure that the CAM software that comes with your system is easy to operate and has enough features. With a few clicks of the mouse, you should be able to:

* Create lead-ins and lead-outs so that the torch starts and stops cutting on the waste side of the profile.
* Set the tool offset so that the torch cuts on the edge of the line.
* Perform autonesting.
* Set the cutting and transverse speeds, pierce and cutting height, and cutting order.

Controller software uses the CAM file that you created to direct the controller to cut your part. It also enables you to manually override the operation with commands like e-stop, back up, and go.

http://www.thefabricator.com/PlasmaCutting/PlasmaCutting_Article.cfm?ID=1642

CNC cutter/profiler uses fuel gas and plasma-arc

2007-12-18T22:54:00.002-08:00

High performance, competitively priced oxy-fuel gas and plasma machine can be fitted with up to four tool carriages, of which one can be dedicated to precision 200A plasma cutting torch

New from ESAB Automation is the Combirex CXL-P CNC cutting machine. It is a high performance, competitively priced oxy-fuel gas and plasma machine that can be fitted with a maximum of four tool carriages, of which one can be dedicated to precision plasma cutting up to a maximum of 200A. The introduction of the Combirex CXL-P underlines ESAB Automation's commitment to providing highly versatile cutting systems that allow customers to maximise the potential of different cutting technologies.

The Combirex CXL-P is supplied with ESAB's Vision LE CNC controller.

This high performance PC based control is designed for fast and easy use.

Along with the graphics, it shows the outside dimensions of the part and gives the operator control for the required area needed to cut the shape.

http://www.manufacturingtalk.com/news/eab/eab109.html

Improvements in Plasma Cutting

2007-12-18T22:54:00.001-08:00

Developments in technology of plasma cutting to better suit consumer needs have helped increase market demand. Improvements in cutting tables linking the CNC and plasma system have helped reduce operating costs.

* Manufacturers of mechanized plasma cutting systems are focused on developing new technologies to meet three key market needs:
o Improved cut quality and consistency
o Increased cutting speeds and material thickness capabilities
o Increased consumable life.
* Together, these three focus areas, along with improvements in cutting tables and automation technology linking the CNC and plasma system, have helped drive reductions in operating costs of modern cutting installations.
* To extend the consumable life of a plasma system equipped with oxygen cutting capability, proper ramping down of gas pressures and power levels needs to occur at the end of the cut. This can happen only when the cut ends on the plate.
* Problems with the gas supply are probably the most common causes of excessive consumable wear. One of the first things a service engineer does when responding to a call about poor consumable life is to run a system gas leak test.
* Gas restrictions causing low flow rates can lead to catastrophic, almost immediate nozzle destruction. Because the initial plasma gas flow is low, the pilot arc attaches to the inside of the nozzle orifice and stays there long enough to cut the nozzle before being forced out of the orifice and transferring to the workpiece.
* In a properly functioning mechanized system, arc transfer occurs within 100 milliseconds. Poor electrical connection from the workpiece to the power supply can delay that to 1� second or more, risking not only increased consumable wear, but also misfiring.
* In most mechanized plasma systems, the connection between the workpiece and the plasma system is through the slats to the table ground, which is where the work cable from the plasma power supply usually is connected.

http://www.used-robots.com/articles.php?tag=1656

Plasma profiler agency for Press & Shear

2007-12-18T22:51:00.000-08:00

Press & Shear has been appointed sole UK agent for Turkish machine tool manufacturer Baykal's range of CNC plasma cutting systems.

The plasma cutting machines have table sizes from 1.5 m by 3 m up to 3 m by 12 m. Other specifications for the plasma cutting machines includes ± 0.1 mm accuracy, 30 m/min axis positioning, ballscrew torch height positioning with patented crash detection, and Windows-based control with automatic nesting capability.

"Most sheet metal sub-contractors and OEMs know us as the UK source for turret punch presses, laser profilers and combination machines from Finn-Power. More recently we have taken on the agency for Italian-built Technojet water jet cutting machines," says Mark Britton, Press & Shear's managing director.

"Baykal's plasma cutting systems neatly complete our portfolio of sheet metal and plate profiling machines, and as they are from one of our existing principals, adoption of the products into our range will be seamless. Our applications and service engineers are currently undergoing training at the factory in Bursa, northwest Turkey."

In 2003, Press & Shear signed a similar agency agreement, which is ongoing, to sell and service Baykal's CNC press brakes.

http://www.machinery.co.uk/article/8932/Plasma-profiler-agency-for-Press--Shear.aspx