FABTECH 2011: METALFORMING

FABTECH 2011 exhibited bending, roll forming, spinning, deep drawing, stretch forming and other sheet metal forming and assembly technologies that are used to bend, stretch and assemble materials into a variety of complex shapes. Now our Show-in-Print brings some of those metal forming systems to you!

Over 35,450 attendees returned to North America’s largest metal forming, fabricating, finishing and welding event in McCormick Place on November 14-17, with over 1,200 exhibitors covering more than 450,000 net sq ft of floor space.

SERVO STAMPING PRESSES
AIDA-America Corporation (Dayton, OH) will be exhibiting and demonstrating two servo presses from its extensive range of metalforming solutions. The first press on display will be a NS2-1600(D) 160 ton capacity straightside servo press. This press will be part of a completely functional line, stamping parts and presented at the show in cooperation with Formtek/CWP, Dayton Progress, AG Tool & Die, and Anchor Danly. The press is provided courtesy of Royal Die & Stamping.

The second press in the AIDA booth will be an NC1-1100(D) 110 ton gap frame servo press, demonstrating its unique ability to reduce reverse tonnage and its ease of operation. Both servo presses will show how AIDA brings maximum flexibility to the pressroom through an infinite number of freely programmable, application optimized, speed, velocity and dwell profiles. Maximized flexibility means maximized production and maximized profit for your stamping operation.

AIDA is a global leader in the design, manufacture, sale, service and support, refurbishment and modernization of metal stamping presses and metalforming automation equipment. AIDA mechanical and servo stamping presses range in capacity from 35 tons to 4,000 tons, from 1 spm to 1,500 spm, from gap frame to straightside, high speed to cold forging, transfer and progressive die, material handling and coil feeding equipment.

AIDA provides one of the broadest selections of complete metalforming systems from a single manufacturer. With a worldwide network of sales and service locations in 36 cities across 18 countries, press installations exceeding 80,000 units in over 60 countries worldwide, producing a range of products for industries such as automotive, appliance, electronic and electrical, AIDA is truly a global metalforming solutions provider.  www.aida-global.com

CNC METAL SPINNING MACHINES
DENN USA Metal Forming and Global Metal Spinning Solutions, Inc. (Colorado Springs, CO) is introducing the high performance line of eSPIN CNC metal spinning machines. With more than 125 years of experience in building metal spinning machines, coupled with the use of the most modern and precision mechanical and electrical components, DENN leads the innovation of a line of fully electrical CNC metal spinning and shear forming machines, called the DENN eSpin CNC metal spinning machine series.

A model eSPIN-100 CNC will be exhibited at the show, highlighting a high precision electrical controlled pressure control, electric tailstock positioning, automatic safety door, 6-tool changer, blank centering unit, blank backup support, part ejector, automatic blank lubrication system, DENN’s CAD-CAM software, remote diagnostic software, preventative maintenance software and much more.

DENN will demonstrate this machine, plus have sample parts, videos and information about our other high precision machinery available, such as flow forming, trimming and beading, rotary forging, wheel forming machines and circle shears. www.dennusametalforming.com

NEW SLURRY BLASTING PARTS CLEANING TECHNOLOGY
New slurry blasting parts cleaning technology from Proceco Ltd. (Montreal, QC), also known as wet blasting, is a patent technology that uses a rotary wheel to discharge a mixture of hot cleaning solution and abrasive media at high velocity to clean and mechanically remove oxides, scale, carbon deposits, oils, and grease from metal part surfaces.

The slurry blasting parts cleaning process can process oily and greasy parts and provides a very clean and smooth finished surface ready for coating, painting, or remanufacturing operations. In addition, this blasting process cleans parts in a short cycle time and without creating dust. Proceco slurry basting parts cleaning technology is available is spinner hanger, tumble blaster and turntable system configurations. www.proceco.com

CUSTOM HYDRAULIC PRESS SOLUTIONS
Greenerd Press & Machine Company, Inc. (Nashua, NH) will showcase their extensive hydraulic press capabilities. Application experts from Greenerd will be available to discuss specific user applications and press requirements.

With product capabilities to 40,000 tons and bed sizes exceeding 240 in (6,100 mm), Greenerd presses are available in a variety of styles ranging from gap frame and straight-side to die-spotting and forging presses. At their manufacturing facility in Nashua, Greenerd recently designed and built a turnkey system including tooling and an indexer for bearing insertion and forming for an industrial hardware application, a 100 ton 4-post metalforming press for an appliance manufacturer with full tooling integration, and a 1,000 ton gib-guided press for coining heavy truck brake components.

Greenerd engineers have years of experience successfully designing presses for a broad range of manufacturing applications. They rely on the latest technologies to deliver the safest, most efficient and reliable machine capabilities. “Our unique strength lies in the relationships we develop with our customers,” said Greenerd president Tim Dining. “We learn as much as possible about the customer’s business, applications and objectives in order to design and build a press that is best suited for their needs.”

Founded in New England in 1883, Greenerd has designed and built thousands of high-quality custom and standard hydraulic presses since 1934. Machines include an extensive line of hydraulic presses in all sizes and configurations. A complete line of arbor presses is also available. Greenerd Presses are made to withstand the rigors of around-the-clock production and deliver many years of service. Greenerd Presses are available as standard machines or can be designed for custom applications by expert engineers with extensive application experience. www.greenerd.com

SPRAY SOLUTION FOR COATING OR SPOT LUBRICATION
Unist, Inc. (Grand Rapids, MI) introduces the LV spray solution which was designed to consistently apply small amounts of fluid in either a fan or cone spray pattern for spray coating applications or for spot lubrication in machining operations. The nozzles are operated with a compressed air input signal and an integral valve at the nozzle tip which allows the pressurized fluid to flow whenever the air signal is present. The volume of both the fluid and atomizing air are controlled with independent precision needle valves.

An optional adapter allows the nozzle to be combined with a rigid copper or flexible plastic extension, allowing for access to tight areas. Nozzles can also be ganged together to create wide area coverage through overlapping spray. Unist offers a variety of pressure tanks, actuation valves, and mounting options which can be combined to form a complete system. Designed primarily to spray lubricants, the LV nozzles are commonly used in metal forming operations, machining, assembly applications, or any place a repeatable amount of lubricant needs to be sprayed.

Formed in 1957, Unist is a leading manufacturer of environmentally friendly lubrication systems designed to reduce fluid consumption while improving operational efficiency in metal cutting and metal forming operations.  www.unist.com

EFFICIENT, ECO-FRIENDLY EQUIPMENT
Magnetic Products, Inc. (MPI; Highland, MI), a worldwide provider of both magnetic and non-magnetic material handling solutions, will display a number of inventive products, including the award-winning Eco-Mag®, a high-intensity magnetic filter which significantly improves filtration efficiency over conventional systems. The Eco-Mag uses high-power neodymium rare earth magnets to remove ferrous and para-magnetic contamination from fluids and is particularly effective with machine tool oils, coolants and hydraulic fluid machinery systems. The environmentally friendly Eco-Mag does not use filter consumables.

With simplicity, adaptability and affordability in mind, patent-pending M-Series Shakers can handle anything from low-volume applications to central scrap removal systems that carry several 1,000 lb per hour. All of these Electric Shakers boast a compact footprint, excellent convey speeds and quiet operation. M-Series Shakers, which operate without the need for maintenance, spare parts or lubrication, cost far less to operate than their pneumatic counterparts.

MPI’s Magnetic Coolant Cleaner boasts a significant improvement in ferrous swarf capture rate. The XCC features an extremely durable stainless steel cleaning surface that will not wear out. Magnetic technology is green, and substantially reduces the need to buy costly consumables and the downtime required to change paper filters.

Beltless Magnetic Conveyors (BLM), available in a variety of models, provide positive control of ferrous metal materials, such as stampings, turnings, chips, fasteners and scrap. Powerful permanent magnets are conveyed below a nonmagnetic stainless steel slider bed to move and convey ferrous metal objects. The liquid-tight sealed conveyor housing can be completely submerged in machine reservoir tanks, while the internal self-adjusting take-up system eliminates the need for maintenance.

The Power Matrix, a high-performance electro-permanent magnetic chuck, offers exceptional power with 150 ton/m² of magnetic pull, enabling huge holding forces to be generated on even modest-sized workpieces. Stepped or shaped workpieces are easily and effectively clamped with optional pole extensions. Power Matrix provides a cost effective way of work holding, enabling users to easily machine a number of faces in one single operation. www.mpimagnet.com

CARBON FIBER TOOLING FOR ROBOTIC HANDLING APPLICATIONS
Bilsing Automation North America, Inc. (Clinton Township, MI) will feature its carbon fiber (Cf) tooling for robotic handling applications. Bilsing’s carbon fiber weighs less than half the amount of traditional materials, yet it is stiffer, stronger and settles more rapidly to enable robot motion paths to occur more quickly, with less vibration and idle time, achieving productivity improvements of up to 20 percent as compared to aluminum and steel tubing.

Potential Cf applications include crossbar beams, loading and unloading beams, destacking beams, panel loading T-booms, and tooling supports for bodyshop, pressroom, injection molding, etc. Bilsing  Cf profiles are compatible with a variety of standard vacuum, gripper and power clamp components. www.bilsing-automation.com

TOUCHSCREEN INTERFACE ENHANCES CAPABILITIES
COE Press Equipment (Sterling Heights, MI) will present its new ServoMaster Touch™ Controller, a next generation controller that features a user-friendly 5.7 in VGA color touchscreen interface with customizable operator screens. New features of the controller include streamlined entry of machine set-up information and enhancements to the operator prompts, machine diagnostics, and serial communications to the press controls – all which contribute to easier use and faster setup.

Additional capabilities include production data reporting of feed cycles and material usage, and downloading of set-up data or job number selection. Its multi-axis capabilities include push-pull, zig-zag and tailout configurations. Auxiliary functions achievable through its Servo Feed Automation Feature include motorized and encoded passline height, motorized and encoded automatic edge guides, feed roll pressure control and material support table position.

Other features of the new ServoMaster Touch controller include:
• Batch counter to 999,999 cycles with output
• Remote job with hand-held pendant for threading
• Continuous jog or jog-to position for threading
• Downloading of set-up data or job number selection
• “Feed Advisor” feature to optimize feed parameters
• “On the Fly” feed length micro adjustment
• 500-job memory storage
• Inch or metric programming
• Serial communications capability
• Password protected job editing and parameters
• English or Spanish language

The new ServoMaster Touch Controller will be the standard on COE servo feed equipment and is also available for existing equipment upgrade and retrofit. www.cpec.com

FASTENERS FOR ELECTRONICS, CAPTIVE PANEL SCREWS
PennEngineering® (Danboro, PA) has introduced a new and growing family of microPEM™ fasteners ideally suited for applications in compact electronic assemblies. These extremely small fasteners can serve as practical, cost-effective, and permanently secure solutions enabling quicker assembly of devices ranging from hand-held consumer electronics to medical equipment, among others.

Standard types of microPEM fasteners include PEM^® Type MSO4™ self-clinching standoffs and PEM^® Type MPP™ self-clinching locating pins. Additional microPEM fastener types from tack pins to screws can be supplied. Type MSO4 standoffs for spacing applications are manufactured from 400 Series stainless steel with threads as small as M1.0/#00 and available in lengths as short as 2 mm/.080 in. The standard product can be installed into sheet metal (including 300 Series stainless steel) as thin as 0.4 mm/.016 in with maximum hardness up to HRB 88 on the Rockwell “B” scale.  Applications requiring installation in sheets as thin as 0.2 mm have also been satisfied with specially engineered microPEM standoffs.

Type MPP micro pins for locating/positioning applications are manufactured from age-hardened A286 stainless steel and designed with diameters as small as 1 mm/.040 in and in lengths as short as 2 mm/.080 in. They can be installed permanently into stainless steel or other sheet materials as thin as 0.5 mm/.020 in with hardness up to HRB 92 on the Rockwell “B” scale. All microPEM fasteners are RoHS-compliant.

New PEM^® Types PF7M™ and PF7MF™ captive panel screws introduce two distinct mounting styles for permanent installation into thin sheets. Both types feature small, compact, and low-profile designs that are ideally suited for limited access areas and benefit from patented MAThread^® anti-cross threading technology that easily corrects off-angle installations, aligns components, and slides through clogged internal threads. Their Phillips recess allows for tool or hand operation.

Type PF7M captive panel screws integrate a self-clinching mounting design providing high pushout resistance.  These fasteners install flush on the back side of panels as thin as .036 in/0.92 mm and are available in two screw lengths with thread sizes #4-40 through #8-32 and M3 to M4. They can install reliably into panels with hardness of HRB 80 or less or HB 150 or less.

Type PF7MF captive panel screws feature a flaring design, which allows them to be installed permanently into any panel hardness with minimal force. Closer centerline (of fastener) to sheet edge can also be achieved with the flare-style mounting.  They install flush on the back side of panels as thin as .031 in/0.79 mm and are available in two screw lengths with thread sizes #4-40 through #8-32 and M3 to M4.

As with other PEM captive screws, both types feature a shoulder on the retainer portion of the fastener to help simplify installation. These new captive screws join a growing family of PEM brand hardware allowing for subsequent access to an assembly. Captive screws remain intact without risk of loosening or falling out and additionally reduce the number of loose parts to be inventoried and handled. www.pemnet.com