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

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

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

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

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

The Prototyp Protostar Ti45 and Ti40 shank-style solid carbide milling cutters from Walter GB provide a universal solution for roughing and finishing cycles.

The Protostar Ti45 has a helix angle of 45 degrees and a cutting-edge length-to-diameter ratio of 5:1.

This configuration makes it ideal for high-speed finishing applications on demanding cycles such as those involving high webs and extended walls within a component.

The cutter is available in 16, 20 and 25mm diameters and with a choice of 3mm or 4mm radii.

Each cutter has a specially developed micro geometry on the periphery of the cutting edge, which enables high orders of surface finish and blend to be created.

Low vibration under cut is a major advantage obtained from the unequal edge-spacing of the Protostar Ti40 end mill when used for rough and finish milling.

As with the Ti45, the specially developed micro geometry on the periphery of the cutting edge creates an enhanced surface finish.

Through pre-treatment of the tool, built-up edge is prevented, which extends the reliability factor of any process and, through a post-coating treatment, which forms part of the ACN coating process, cutting-edge life is also increased.

Available in diameters between 12 and 25mm, the Prototyp Protostar Ti40 can also be specified with radii of 0.2, 2, 2.5, 3 and 4mm set at the transition point between the primary and secondary cutting edges.

Both tool types are also available in imperial sizes.

Milling cutters have wavy helix configuration

Cutwel has introduced solid carbide milling cutters from YG-1 for machining stainless steels, titanium alloys, inconel, tool steels, cast iron, mild steels and low hardness materials under HRc 40.

The cutter is made from a K30/K40 premium-grade carbide and a variable helix geometry has been manufactured into its flute form.

The V7 cutters have a wavy (sinusoidal) helix configuration and the index and helix on each portion of the cutting edge changes along the flute to give smooth cutting and chip removal.

This helps to reduce vibration and produce silent machining; improve surface finish due to the chatter-free design; increase cutting depths and give higher feed rates; and makes it possible to rough and finish with one cutter with minimised tool deflection and take a depth of cut equal to the cutter diameter.

It also features corner radius cutters for strength and protection against chipping and an Altin coating to reduce friction and dissipate any heat during cutting.

Application cutting area: stainless steel: 80-100m/min; titanium: 80-90m/min; inconel: 20-30m/min; alloy steels; and cast iron: 120-150m/min.

Seco releases PVD-coated MP3000 grade for steels

Seco Tools has brought out the MP3000 milling grade, which provides optimal performance in milling steel and tool steels with relatively thin average chip thickness.

The new grade is especially effective in square shoulder and copy milling applications where wear resistance and tool life need to be improved.

In these applications, MP3000 has shown a 40 per cent increase in tool life and up to a 200 per cent increase in machined components as compared with competitive steel machining grades.

The new MP3000 cemented carbide makes the grade hard and tough.

A slightly thicker PVD coating increases wear resistance over a large application range and an improved coating process increases coating adhesion, edge quality and edge integrity.

Although developed to enable higher speed capabilities in milling of steels, MP3000 is also suited for use as an optimising solution for machining of stainless steels and heat-resistant alloys.

The new grade is offered in a range of insert geometries to cover face, square shoulder and copy-milling applications.

It is especially effective when paired with Seco's new Square 6 milling cutter, serving as a first-choice tool for a variety of general machining operations.

Seco Tools is part of Seco Tools AB (Fagersta, Sweden), a world leader in metalworking technologies.

Horn to exhibit DAH milling cutters at EMO

Horn Cutting Tools will showcase its products at the forthcoming EMO 2009 in Milan, in partnership with Italian partner Febametal SpA.

The exhibits will include ground-in chipbreaker technology to maximise the performance of Supermini boring tools, as shown in the new HV geometry.

Among the all-new Horn products on show in Milan will be a range of milling cutters for high-feed milling applications and a range of high-precision reamers.

The new DAH milling cutters have been developed for requirements in tool making and mould making for roughing with high feed rates and low cutting depths.

The inserts ensure optimum distribution of the cutting forces as they act to transfer cutting forces in an axial direction and thereby reduce the spindle load.

Depending on the material, feed rates up to 3mm/tooth can be achieved for a maximum cutting depth of 1.2mm.

The triple-edged inserts are available in carbide-grade SA4B, which offers high wear resistance for milling steel and cast materials.

The titanium nitride (TiN) coated holders have through-coolant capability and are available as end mills with Weldon toolholder and as industry-standard threaded connection cutters with the MD holder design already tried and tested in the DA system.

The new DAH milling system features cutting-edge diameters of 20, 25, 32 and 40mm.

Existing Horn milling systems for 0.2 to 32mm diameter comprise the solid-carbide DS milling cutters, the DM combined milling cutters and the DA round-shank and industry-standard threaded connection milling cutters with triple-edged indexable insert.

Horn is also introducing the DR Reaming range of precise reamers.

The range is being produced under licence from the Swiss company Urma AG in Rupperswil and comprises of cutters, inserts, adapters and alignment aids.

A major feature of the DR reamers is the narrow, patented cutters for precision machining of steels, cast materials, non-ferrous metals and plastics.

They are available with cutting-edge diameters from 11.9 to 100.6mm in coated carbide, non-coated carbide and cermet versions.

All diameters are available with IKD straight-tooth geometry for reaming through-holes and IKS left helical rising-tooth geometry for reaming blind-hole drillings.

Depending on the material to be machined, four cutting geometries for the straight-tooth versions and two for the helical rising-tooth variants can be selected.

A positioning pin and screws with specified torques on the face side allow the cutter to be quickly changed.

Adjustable chucks simplify checking and adjustment of concentricity.

The cutter holders are available as cylindrical shank with internal coolant supply in short and long versions with diameters from 11.9 to 35.6mm.

Shanks with diameters from 35.6 to 100.6mm have their own alignment mechanism.

Cutwel unveils YG-1 solid carbide milling cutter

Cutwel has introduced an advanced solid carbide milling cutter from YG-1 for machining hardened steels, stainless steels, alloy and non-alloy steels, cast iron and heat-resistant steels up to HRc 70.

This new-generation X-Power cutter is made from a fine micrograin premium-grade carbide, which is processed in high-temperature furnaces.

These furnaces enable the carbide to be manufactured with a consistent carbide grain structure with no porosity.

After cooling down, the carbide is said to be very tough.

The hard PVD coating on the X-Power carbide cutting tools was developed for its good thermal and chemical stability, making it suitable for high-speed machining on high-hardness materials under extreme cutting conditions, making these cutters ideal for dry cutting.

It is recommended for tool making, mould and die, aerospace and the automotive industry.

The coating helps to protect the tools against premature wear and is suitable for running lights out or on long cutting cycle times.

This enables fast chip removal.

Cutter sizes range from 0.4mm to 25mm in diameter.

Ball nose cutters are ideal for machining difficult-to-cut complex 3D forms.

Corner radius cutters provide strength and protection against chipping.

Six- and eight-flute 45-degree helix cutters are available in long and extra-long sizes.

Miniature cutters are available for machining small complex features.

Two- and four-flute cutters are offered for slotting and side cutting.

Dry cutting is claimed to reduce the need for expensive coolants and productivity is maximised with increased speeds and feeds.

A long tool life is said to be guaranteed thanks to the X-Power coating, which protects against premature wear.

All cutters provide excellent component surface finish, according to the company.

Faster cycle times also lead to cost savings.

Full technical back-up is offered on cutter selection, speed feeds and recommended depths of cut.

Kennametal unveils shrink-fit toolholding system

As part of its complete tooling solution from the spindle face to the cutting edge, Kennametal has announced its shrink-fit toolholding system for machining centres and multi-tasking machines.

The shrink-fit system is split in two lines.

With the GP (general purpose) line, carbide, HSS and steel shanks can be accommodated with clamping torques suitable for most general engineering, die and mould, automotive and other machining tasks.

For heavy roughing operations requiring a higher clamping torque level, or for machining difficult-to-cut materials such as those found in the aerospace industry, the HT (high torque) line is recommended.

The HT line has a 30 per cent to 50 per cent higher clamping torque compared to the GP line.

The results are improved chip removal, faster performance and increased productivity for the end user.

For tolerancing hollow-shank (HSK) toolholders, taper is much tighter than that of any conventional 7/24 taper shanks.

For example, with a HSK63A, the taper tolerance is around several microns.

'Due to the trend toward higher cutting speeds, all the latest HSK shrink-fit toolholders have a balancing quality of G2.5 at 25,000rpm,' said product manager Oliver Moeller.

The Kennametal shrink-fit programme also accommodates steep taper, BT, CV and DV back ends.

According to Kennametal, the key features are: a very rigid and accurate connection to the tool holder; a shrinking and cooling process that will not last more than 30 seconds; very precise concentricity (3um); major process advantages in milling operations; slim profile for chucks for milling deep cavities; through-hole for coolant; and axial adjustment/backstop; and accommodates roughing, semi-finishing and finishing operations.

WNT extends Ultramini grooving tool range

WNT's range of Ultramini solid carbide grooving tools has been extended with axial and radial grooving tools and the addition of a high-pressure through-coolant facility.

The range of axial (face) grooving tools benefits from two integral coolant holes capable of accepting coolant pressure up to 100 bar.

Face grooves down to 3mm wide, at diameters over 16mm, can be cut up to 40mm deep, as the high-pressure coolant ensures that swarf is efficiently and reliably evacuated from the groove.

Axial grooving tools without through coolant are available down to 1mm in width.

the axial grooving range also uses a K10F TiAlN-coated carbide that has been developed with this type of application in mind.

A two-micron thick coating helps to achieve a sharp cutting edge geometry to reduce vibrating and minimise chatter, while extending the life of the cutting edge.

The Ultramini radial grooving tools can be also specified with through-tool coolant.

Available in groove widths from 1.0 to 3.0mm to cut grooves up to 30mm inside a bore, the tools also make use of the K10F TiAlN-coated carbide.

Both axial and radial tools are held in a steel body that features a fixed backstop, with the accuracy of the cutting tool being such that they repeat within microns, allowing tool changes to be completed quickly, with no need to alter the backstop or tool offset.

ESAB launches CNC plasma-arc cutting power source

ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.

The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.

The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.

High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.

Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.

Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.

Cutting and marking operations can be carried out with the same consumables.

The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.

ESAB introduces Falcon cutting machine

The Falcon entry-level compact cutting machine from ESAB Cutting Systems can be fitted with oxy-fuel cutting torches or can be supplied as an oxy-fuel package prepared for plasma-arc cutting.

Small engineering businesses can use this capability to produce quality steel construction and cut components in-house rather than using a subcontractor.

With its integrated CNC system, Falcon offers a fast, flexible, automated cutting solution capable of producing cut components on demand.

It is a suitable choice for workshops where space is at a premium and is designed to cut plate sizes up to a maximum of 2m x 6m with positioning speeds of up to 9m/min.

The Falcon has the option of being upgraded at a later date to a different process for specific cutting tasks.

Depending on the cutting process selected, it can cut steel, aluminium and alloyed steel up to 100mm thick.

The CNC system contains a cutting database with 65 programs for reproducible quality and high productivity.

Other features include two installed workpiece carriers with quick-release connections for easy positioning, plus a transverse and linear drive system with three-phase current for high cutting accuracies over the entire cutting range.

Copies of the latest Falcon literature are now available from ESAB Cutting Systems.

Autodrill adds option to cutting machines

Autodrill has enabled a manufacturer of oxyacetylene cutting machines to offer a hole drilling option.

Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.

By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.

The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.

Annular cutters with a positive plug ejection system can also be used for some applications.

All the equipment is rated for continuous duty production work.

Autodrill offers free application and design assistance during the quote and post-sale process.

Free CAD drawings are available for all equipment.

A search for Autodrill on Youtube and other video sites turns up a number of example videos.

ESAB PDM tracks cutting system performance

ESAB Cutting Systems production data management system (PDM) is designed to control, track, record and report the performance of a cutting system in real time.

It allows data related to cutting and marking process to be captured and interfaced with existing business-planning systems.

By making production performance transparent, operational costs can be lowered and cycle times can be reduced.

The PDM system has a number of different modules that can be added as required.

These modules include PDM Workshop View, which provides automatically updated visualisation of all cutting machines connected to the PDM system.

It gives a detailed view of current and historical machine processes and performance.

The PDM Maintenance module records wear and usage of consumables while the PDM Event Control database records machine downtime and error messages.

When combined, the various modules give fully automated machine data logging and can plan detailed working orders for each cutting machine to maximise productivity.

PP Plasma uses ESAB submerged plasma cutter

PP Plasma, a specialist in plasma, laser and waterjet profiling, has invested in an ESAB Cutting Systems Suprarex SXE P2 submerged plasma cutting machine for its purpose-built premises in Salford.

It has replaced two existing plasma machines and has given the company the capacity to deal with the demand for its products and services from many industries, including aerospace.

PP Plasma cuts stainless steel, aluminium and titanium in material thicknesses from 1mm to 150mm.

The Suprarex SXE P2 is predominantly used for stainless-steel grades in thicknesses ranging from 26mm to 100mm.

It is an underwater plasma profiling machine and this provides PP Plasma with environmental benefits, helping it to comply with legislation, since noise, fumes and glare are eliminated by cutting underwater.

The machine is equipped with the ESP 600 plasma 750A power source, which is regulated automatically depending on the thickness and the type of the metal to be cut.

A Vision 52 CNC control system has also been supplied - this automatically controls all the plasma cutting functions from its database to ensure optimum cutting quality without operator intervention.

Changeover and setup times between different thickness changes are kept to a minimum.

Gas selection and pressures are also changed automatically to ensure the best quality of cut.

NUM to exhibit tool head and 3D simulation package

NUM will launch a ready-integrated tool head for sophisticated plasma-arc, laser and waterjet cutting machinery applications at EMO 2009, which is scheduled to take place in Milan on 5-10 October.

The CNC controls vendor also plans to exhibit an advanced 3D simulation package combining workpiece simulation with collision monitoring.

A novel mechanical design means that the new tool head provides the versatility of movement and stiffness required to implement a precision cutting motion, but with the advantages of very low mass and the elimination of cabling runs that must flex with the tool head movement and that can cause failures.

As a result of its light weight, the head can be assembled on existing CNC machines in the plasma- and waterjet-cutting market, often without additional mechanical adaptation, providing a simple means of extending the capability of machinery from 2D to 3D applications, with precise multi-axis interpolation.

NUM's 3D simulation package, meanwhile, combines workpiece simulation with collision monitoring and other powerful features.

The computer-aided-engineering (CAE) software allows machine builders to offer new generations of optimisation tools with their machines to help users maximise manufacturing throughput and productivity.

Designated True 3D, the software tool is a general-purpose version of NUM's 3D simulator for multi-axis grinding applications.

The new software is not only emulating but is simulating the actual CNC commands, hence the name True 3D, and subsequently provides an output as close as possible to the actual machined parts.

It allows machinery users to virtually prototype and optimise the entire machine production process to yield significant gains, including improved machine productivity, reduced tool wear and faster project completion.

M3 plasma cutting system offers quick installation

ESAB Cutting Systems' M3 plasma cutting system is a complete high-performance system that is quick and easy to install and demands little in terms of operation and maintenance.

It offers a range of functions including marking and labelling and new cutting torch features have widened the scope of applications and improved cutting quality.

The latest PT-36 plasma-arc torch can replace up to three single-purpose torches and consumes fewer wear parts.

It enables the M3 plasma to carry out the high-quality precision cutting and marking of thick plate.

The torch can handle cuts of a variety of geometrical shapes, bevel cutting with a weld bevel angle of zero degrees to +/-45 degrees and the most common marking and labelling tasks.

The cutting thickness depends on the M3 plasma power source used and ranges between two and a maximum of 60mm in constructional steel, stainless steel and aluminium.

As an option, the PT-36 plasma-arc torch can now be upgraded for cuts up to 150mm in stainless steel and aluminium.

The M3 plasma system also uses ESAB's so-called shield gas technology, in which a secondary gas, such as oxygen or nitrogen, is used alongside the plasma gas, circulating around the arc and providing it with a protective, stabilising shell.

The result is a fine, accurate arc that has greater density and stability in comparison to conventional processes, according to the company.

This leads to higher cutting speeds, more precise cut edges and high-quality cut surfaces.

Small to medium-sized sub-contracting and manufacturing companies are said to be benefiting from the advantages of plasma-arc cutting thanks to falling costs and continually improving technology.

Brown McFarlane buys ESAB plasma power sources

Brown McFarlane of Stoke-on-Trent, a distributor and processor of steel plates, has invested in plasma power sources from ESAB Cutting Systems.

These are retrofitted to an ESAB Suprarex machine, which was originally acquired in 1995.

Brown McFarlane, which has a large ex-stock range of carbon and stainless plates, serves a variety of markets including process engineering, mining and the nuclear- and renewable-energy sectors.

The latest installation demonstrates how the incorporation of modern plasma-arc power sources into existing profiling technology can provide major benefits.

The Suprarex is regarded as the mainstay of Brown McFarlane's carbon steel profiling operations.

It is one of a number of plasma-arc profiling machines operated by the company for cutting both mild and stainless steel.

Brown McFarlane has invested in planned preventative maintenance and the upgrading of key components on a regular basis to enhance performance and ensure reliable operation.

This has included the renewal of the machine's rack and pinion drives and a new Vision 52 NC controller.

Now, two new 400A plasma-arc power sources have been added, replacing existing 200A sources, bringing extra power and higher cutting speeds as well as producing high-quality cuts that are dross free and with a minimal heat-affected zone.

The retrofitting of the two plasma units took three weeks at the Brown McFarlane plant at the start of 2009.

The Suprarex was completely stripped down and effectively rebuilt from scratch.

It is being used to pierce and cut mild steel from a thickness of 0.5mm to 50mm, up to 100mm from the material's edge.

The Vision 52 controller, with its LCD monitor and ergonomic keyboard, is said to be simple to use.

Its fully integrated database allows Brown McFarlane to set up fully automated production cycles that require no extra manual settings or operator intervention.

The optimum cutting parameters and speeds are set automatically for materials and thicknesses to be cut with and all cutting processes are controlled by the Vision 52.

In this way, Brown McFarlane is assured of both maximum productivity and maximum quality.

Autodrill adds option to cutting machines

Autodrill has enabled a manufacturer of oxyacetylene cutting machines to offer a hole drilling option.

Because making small, accurate holes through thicker material is sometimes impossible with a laser unit, the manufacturer researched putting an automatic drill on its machine.

By drilling all the holes with a standard Autodrill machine, smaller holes are now possible through even the thickest materials due to the optional peck drill features available.

The customer is also considering placing multiple spindle drill units on a single fixture, to drill many small holes at the same time.

Annular cutters with a positive plug ejection system can also be used for some applications.

All the equipment is rated for continuous duty production work.

Autodrill offers free application and design assistance during the quote and post-sale process.

Free CAD drawings are available for all equipment.

A search for Autodrill on Youtube and other video sites turns up a number of example videos.