FABTECH 2011: Forming & Fabricating (Part Two)
FABTECH 2011 exhibited many production technologies and techniques for OEM manufacturers and contract job shops that add value to sheet metal, coil, plate, tube or pipe stock by shaping, bending, forming, punching, welding, cutting, fabricating, assembling, or other processes. Now our Show-in-Print brings some more of that forming and fabricating equipment to you!
Posted: November 30, 2011
Material management within the CT-P unit is easily controlled via LVD Strippit’s touch screen graphical user interface providing an intuitive man machine interface. Strippit V, VT, M and VX-Series turret punch presses are engineered as automation-compatible and can be easily integrated or retrofitted with the tower unit.
LVD Strippit also offers precision ground tooling with its patented STONE® radius for LVD Strippit press brakes. STONE tooling (“Shaped Tooling for Optimal beNding without wEar”) is produced with a progressive radius on both sides of the V-opening, allowing the material to flow into the die more evenly and with less drag. The STONE radius assures accurate bend angles along the entire bending length. The unique design of the V-die reduces the friction between the material and the die encountered when bending by creating a rolling condition as the material enters the die.
STONE tooling also diminishes marks, nicks and carbon deposits that can occur on the workpiece as the material rolls through the die. Tooling benefits include reduced tool wear, tool interchangeability, reduced residue on stainless steel, improved material control, reduced tonnage requirements and symmetric bending. www.lvdgroup.com
HIGH SPEED LASERS CUT SHEET, TUBE, PIPE
Mazak Optonics Corporation (Elgin, IL) will showcase a wide range of applications and demonstrate several new machines. In fact, show attendees will be the first to witness Mazakʼs inaugural fiber laser. Built on the companyʼs OPTIPLEX platform, this laser achieves extremely high speeds via an IPG fiber resonator, which yields faster cuts through thin gauge material and significantly reduces operating costs.
The new OPTIPLEX 2D laser cutting system with flexible 2-pallet changer provides high throughput, AO/5 automated setup technologies and rugged construction. By combining integrated intelligent automation and superior cutting speeds, this job shop laser accurately processes material thicknesses from the thinnest of steel to 1 in mild steel. During booth demonstrations, show attendees will experience the machineʼs new user-friendly PreView II touch screen control and new 4,000 watt Type 10 resonator that lowers operating costs.
Visitors to the Mazak Optonics booth will also get to witness the new performance power of the SuperTurbo-X Mark III. The company took this already popular laser cutting system and made it even more advanced by increasing its power output to 6,000 watts. This boost allows the system to meet the unique demands of processing thicker mild steel and stainless materials.
Mazak will also introduce its new modular material automation system that is expandable from one up to four laser-cutting machines. For the purpose of catering to specific operational needs, this modular system offers a variety of loading tables, stocking towers up to 40 shelves, unload stations and workpiece storage towers. The new line controller helps increase system flexibility and improves throughput.
Lastly, show attendees will get to observe the companyʼs STX Mark III RTC, which expands laser services beyond flat plate. This unique 2D laser system integrates a rotary chuck for tube and pipe cutting with the ability to tap and chamfer in a single setup on one machine. www.mazakoptonics.com
FAST HIGH PRECISION WATERJETS
OMAX Corporation (Kent, WA) will showcase its wide breadth of abrasive waterjet product offerings, starting with demonstrations of its premium 80X JetMachining Center® equipped with an EnduroMax™ pump and Tilt-A-Jet® cutting head, as well as its cost-efficient, highly productive MAXIEM® 1530 JetCutting Center with a multi-axis A-Jet™ accessory and a powerful and efficient direct drive pump.
Ideal for precision machining of larger or multiple parts, the 80X JetMachining Center is equipped with the patent pending Intelli-TRAX®, an innovative drive system developed specifically for abrasive waterjet machining to ensure high accuracy. The drive is fully enclosed inside coated steel covers, making the 80X a robust and reliable system that is well suited for harsh environments and requires little maintenance. Additionally, the Intelli-TRAX traction drive enables faster traverse speeds than traditional drive systems and greatly reduces processing times when machining multiple and nested parts.
The 80X features an X-Y travel of 165 in x 80 in (4191 mm x 2032 mm) and comes standard with Intelli-MAX® Software that runs on the Windows® 7 Ultimate operating system. The system can calculate the precision of the velocity of a tool path at over 2,000 points per inch, allowing for complete control over the motion of an abrasivejet, and enabling precise, rapid machining.
Like all JetMachining Centers, the 80X has the ability to cut a wide variety of materials, including ceramics, composites, plastic, glass and stone, as well as metals such as aluminum, tool steel, stainless steel, mild steel and titanium with an accuracy of motion up to ±0.003 in (0.076 mm). The 80X will be equipped with the revolutionary 50 hp EnduroMAX pump, which is making its FABTECH debut, and the Tilt-A-Jet cutting head accessory. Show visitors will see these two highly successful technologies in action and discover how they further advance the abrasive waterjet cutting process.
The EnduroMAX pump provides double the operating life of previous pumps, and makes for faster part processing, lower operating costs, and easier maintenance. It maximizes machine uptime with its 1,000 hr operating range between required pump rebuilds when run at 55,000 psi (3,800 bar). However, the pump can also effortlessly run continuously at 60,000 psi (4,100 bar).
The EnduroMAX pump operates at 90 percent efficiency, as opposed to the 60 percent to 70 percent range of intensifier pumps. This means it delivers more horsepower to the nozzle than even 87,000 psi + intensifier pumps for the same installed electric horsepower. Higher nozzle horsepower due to 90 percent efficiency of the EnduroMAX direct drive pump allows OMAX machines to process parts faster by delivering nearly the full motor power to the nozzle. EnduroMAX are the most efficient waterjet pumps developed, regardless of pressure. They are offered in various horsepower ratings. The available models are the 3060 (30 hp), 4060 (40 hp) and 5060 (50 hp).
The Tilt-A-Jet cutting head allows JetMachining Centers to achieve virtually zero taper. By automatically calculating and adjusting the angle of the nozzle through the controller software, the Tilt-A-Jet transfers taper from the part being cut to the scrap material. Attendees will experience the precision, reliability and efficiency of the company’s value-inspired MAXIEM 1530 JetCutting Center, which is ideal for fabrication shops, metal service centers, trade schools, job shops, architectural, sign, stone and gasket shops.
The MAXIEM 1530 will be equipped with a high-pressure direct drive 50,000 psi pump in a 30 hp configuration and an A-Jet multi-axis accessory that cuts beveled edges and angles with an articulated jet. Show visitors will see how the accessory readily cuts various angles in one tool path by simply determining the cutting parameters in the machine’s easy-to-use controller software. Like the 80X JetMachining Center, the MAXIEM 1530 features the critically acclaimed Intelli-MAX Software and Intelli-TRAX precision drive system.
With a slat bed size of 151 in x 69 in (3,835 mm x 1,752 mm) and a maximum table load of 25 lb per sq ft (1,221 kg/sq m), the MAXIEM 1530 productively cuts a wide variety of materials without creating heat-affected zones or mechanical stresses. By cutting parts directly from the plate, the MAXIEM 1530 also dramatically reduces setup time and material usage. The MAXIEM product line’s X-Y cutting travel ranges from 30 in x 30 in (762 mm x 762 mm) to 160 in x 79 in (4,064 mm x 2,006 mm). www.omax.com
BATCH BLAST MACHINES HAVE NO PINCH POINTS
RMT multi-tumbling batch blast machines from Rosler Metal Finishing USA, LLC (Battle Creek, MI) are designed for continuous performance and low maintenance. Using a special rotary barrel design, these durable units produce excellent blast coverage results and compared to conventional tumblast machines, they have no “pinch points” to damage even sensitive parts.
The RMT also features a simple design with few moving parts ensuring high up times and low maintenance costs. Easy automation with custom-made loading and unloading equipment make integration into existing systems a breeze. Plus, with the rotary barrel made of highly wear-resistant manganese steel, RMT machines provide years of reliable service. Rosler’s RMT machines suit every capacity requirement from 3 cu ft to 34 cu ft batch sizes and include a wide choice of blast turbines from 15 hp to 75 hp. www.rosler.us
A WORLD OF SAFETY MATS
For over fifty years, Tapeswitch Corporation (Farmingdale, NY) has been engineering switch products, systems, and solutions for hundreds of machine safety applications throughout the world’s leading manufacturing industries. These switch products connect to machinery to assist in the manufacturing of goods in accordance with safety standards and in the protection of assets that include the safeguarding of areas and people, equipment, and machinery.
Tapeswitch Corporation safety switch mats are engineered to provide over 3 million actuations at any point and are fail-safe protected. Standard actuation forces range from 22 lb (100 nominal) to 66 lb (300 nominal) mats, engineered in accordance with EN17601 standards.
Tapeswitch offers a complete product line of safety mats that includes abrasion resistant (ControlMatTM) mats, puncture proof and impact resistant (ArmorMatTM) mats, high impact, aluminum plated (Diamond PlateTM) mats, anti-fatigue (Comfort ZoneTM) mats, and molded (parallel plate) models. These product lines can also be custom engineered in a variety of sizes, large areas, different shapes, long lengths, various colors, different edges, different lead point connectivity, curves and angles, and cutouts.
Completed safety mat systems switch product solutions are constructed along with safety interface modules. These safety interface modules can control operation of single or multiple safety switch mats, detect faults, and are fail-safe. Together, the safety mat and safety interface module provide a complete machine safety system. These systems can be engineered to fit safety applications and different machinery in fabricating operations.
Tapeswitch engineers work side-by-side with OEMs, engineers, plant managers, safety professionals, purchasing managers, end-users and all levels of the engineering process within in most industries to custom engineer high-quality switch products that take on many forms and meet industry standards and specific applications at affordable prices. They have the shortest lead times for standard and custom built safety mats products. www.tapeswitch.com
POLISHING, DEBURRING, SLAG GRINDING
Hans Weber Sales & Service (Olathe, KS) will be displaying information on their line of polishing, deburring and slag grinding machines. Weber’s modular machine construction gives customers the versatility they need to operate abrasive belts, scotchbrite, planetary disc stations or polishing platens to attain the surface finish they need.
Visitors to the Hans Weber booth will have an opportunity to learn about their full line including the TT series of finishing and grinding machines with the patented DR planetary disc which handles laser oxide film removal or precision edge rounding. For dry metal working of medium and coarse plates, these grinding machines are fitted with a Combination STC (combination station) with grinding roller and pin grinding beam. Disk stations or planetary heads can be added for edge rounding.
The combination station works with three different material removal techniques and can compensate the higher tolerances of a few millimeters that occur with thicker sheets. It works without any secondary burr generation. Reworking with Multidisc station MD or Planetary head DR can achieve the required edge rounding in the case of plasma and laser cuts.
For large dimensions, the pin grinding beam STC-E can be fitted with an electronic controller, which limits the material removal to the edge zone. These machines can work from the top and bottom. With Weber machines customers can round edges, deburr, remove laser oxide film and finish all in a single pass. Weber has been manufacturing reliable, durable, quality grinding machines for varied applications for over 90 years. weberamerica.com
ORBITAL STRETCH WRAPPING
Yellow Jacket (Douglasville, GA) will display their 87 in diameter Manual Yellow Jacket Orbital Stretch Wrap Machine for securing standard, oversized or odd-shaped palletized loads while the pallet remains on the forklift. A horizontally positioned stretch-wrap dispenser moves around and under a load as the Yellow Jacket is manually advanced across the length of the load.
The 87 in Manual features adjustable tensioning for a range of 0 to150 percent film post stretch and standard machine wraps a standard pallet size up to 68 in diagonal. Other orbital stretch wrap technology machines and equipment will also be discussed at the show.
GaleWrap markets Yellow Jacket brand orbital stretch-wrapping equipment and services that locks loads to the pallet, offering a quick and secure wrap to protect loads against damage, dust and wind. GaleWrap also offers GaleWrap® Oriented Film and Oriented Equipment as an alternative to conventional hand wrapping. GaleWrap Oriented Film and Equipment offer increased wrapping productivity, enhanced employee safety, improved load containment and lower total pallet wrapping costs. www.yellowjacket110.com, www.galewrap.com
Subscribe to learn the latest in manufacturing.
