Cranfield University's production trials have revealed potential costs saving using High Efficiency Deep Grinding - or HEDG - technology in the plunge grinding of automotive crankshafts.
Cranfield University's School Of Industrial and Manufacturing Science, Cranfield, UK, has employed a Holroyd Edgetek SAT super abrasive grinding machine as part of a three year programme to develop a deeper understanding of the mechanisms of metal removal using HEDG (High Efficiency Deep Grinding technology). The investigation culminated in a series of tests on a Cinetic Landis LT2 used to cylindrically plunge grind automotive crankshafts with metal removal rates up 1000mm3/mm.s. No thermal damage to sidewalls was recorded.
Achieving these increased removal rates has unlocked the potential of rough grinding to make the HEDG process competitive against more traditional methods.
The study at Cranfield was a collaborative project sponsored by EPSRC between the University, Holroyd, Cinetic Landis Grinding, St Gobain, Liverpool JMU, Castrol, Stesstech, and Element 6.
It was organised and undertaken under the direction of Professor David Stephenson, a world authority in grinding technology.
'The objective of our research was to establish a model which explains the thermal characteristics of metal removal under HEDG conditions and then apply this to machining standard automotive crankshafts,' said Prof Stephenson.
'Many production engineers are aware of the potential that exists to optimise existing industrial process chains using today's high performance grinding machines and the latest super-abrasive technology'.
'HEDG is one such example; its high material removal rate offers the potential to improve cycle times whilst maintaining surface integrity, form and finish requirements.' One of the key requirements on automotive crankshafts is that the pins and mains both require journal diameters and web sidewalls to be ground.
The pins require wide short path grinds, typically using high spindle power levels, while the mains need narrow and longer path grinds, which are not normally limited by the available spindle power, but by issues of thermal damage.
The major ramification of this is that the webs or sidewalls of the crankshaft are particularly suitable for the application of HEDG technology.
HEDG delivers improved 'Burn Threshold' qualities that result in lower grind temperatures of the workpiece, and overall improvement in the quality of the finish itself.
In addition, HEDG offers great potential to improve process times and, as a consequence, helps manufacturers to gain a competitive advantage.
The Cranfield research comprised grinding trials, which were carried out in two stages: initially utilising test-pieces in a laboratory environment, followed by automotive crankshafts on production machinery.
The test pieces themselves were selected steel and cast iron materials.
One of the major issues faced by the research team was that, in order to increase specific material removal rates (Q'w) to levels far higher then currently used commercially, it was necessary to understand how the heat energy is partitioned to the workpiece.
This was achieved using thermal models specifically developed for high removal grinding; and by employing a novel temperature measurement technique adapted for cylindrical grinding.
During the initial work, tests were carried out over a range of Q'w from 100 to 2000mm3/mm.s on steel samples.
Power data were recorded and then used to predict surface temperatures using the thermal model.
A second set of trials was then carried out on production machinery with both steel and cast iron crankshaft components.
A similar range of Q'w rates was investigated.
In this case the simple shaped grinding wheels were replaced with two fully profiled left and right hand wheels, to enable the production of the undercut form, blending sidewall and diametrical features, and any differing width requirement.
The initial set of trials was conducted using a Holroyd Edgetek SAT super abrasive turning machine, while the second set, which were validation trials, took place on an LT2 machine at the Cinetic Landis factory, under actual production conditions.
The CNC controlled Edgetek system provides cutting speeds of up to 12,200m/min, courtesy of a high power, variable speed 37kW spindle motor operating at 9000 rev/min max, and CBN electroplated wheels, which provide long wheel life.
Coolant nozzle design had to be improved too.
Delivery of the correct amount of workpiece coolant and lubricant to the work zone is important to reduce the heat being transferred into a workpiece.
The Edgetek machine is fitted with a very stiff grinding spindle, which uses hybrid ceramic bearings that facilitate the very large cuts possible with HEDG.
In addition, the granite polymer composite base offers excellent damping properties, virtually neutralising resonant frequencies within the machine that could impair its accuracy.
The result of this synergy is a machine that allows heavy stock removal on straight outside diameters (ODs) or special form diameters to grinding machine tolerances on virtually any difficult material or Rockwell hardness.
* Results - the results for both the initial and production stages of the trials correlated well.
The industrial application of the process initially considered a small number of steel crankshafts ground over a range of Q'w, and then a batch of 1000 with a constant stock removal rate.
The batch run demonstrated process stability with grinding power levels remaining consistent throughout.
Crankshafts were checked for form and surface finish requirements and remained well within specification; typically 50 micron for concentricity and 2.3 micron Ra for surface finish.
The application of the increased removal rates - 1000mm3/mm.s for sidewall and 200mm3/mm.s for diameters on the crankshafts, offers the potential to save cycle time in full production for both steel crankshafts and cast iron crankshafts.
In addition, even with the increased removal rates, the specific grinding energy (SGE) versus Q'w relationship showed a similar trend to previous surface HEDG investigations, with the SGE reducing at higher Q'w values.
This means that a greater proportion of the energy is removed by the grinding chips, resulting in a reduced energy input to the workpiece within the HEDG regime.
Summing-up the results of the trials, Prof Stephenson said: 'Our study has shown that the performance level of standard production machinery currently in use within the automotive industry can be extended to provide a number of major advantages'.
'These are, firstly, more efficient grinding regimes that compete with conventional cutting processes in terms of stock removal rate; secondly, reduced manufacturing costs as a result of higher production rates and lower capital investment; and thirdly, improved surface integrity and, therefore, better component performance and reliability due to relatively low workpiece temperatures.
Saturday, April 21, 2007
Saturday, April 14, 2007
CNC punch press choice based on experience
A generous specification for a cost-effective price and a short delivery time led to the choice of another CNC punch press by a switchgear manufacturer, based on past experience.
Howarth Switchgear has built its business on providing exactly what customers want when they want it, and to give it the capacity and flexibility to meet these demands it has just invested in a new LVD Parma 1212 CNC punch press. Director Chris Howarth says that the key arguments for the Parma were that it gave a generous specification for a cost-effective price and a short delivery time. He was also convinced it would be reliable, as the company had been running a punch press from LVD's predecessor Shape Machines for the past twenty years with very few problems - and those problems that did occur were fixed very quickly.
'The Shape machine has worked well for us with very few breakdowns, but we thought it was time to move on,' he said.
Howarth's business is building electrical switchgear systems for all kinds of non-domestic premises - from banks and call centres to chemical plants, food processors and military installations.
And even though they try and incorporate standard elements, no two systems are the same.
'Every building is different and the system requirements in buildings are changing all the time,' said Howarth.
'If you are refurbishing a building you are going to need 100 to 150% more power because everything now is IT-oriented.
And if you have more computers you need more air conditioning to deal with the heat they give out.
The result is that they end up trying to get much more switchgear into the same space as they used before.
So it all has to be specially built.
The other problem is that sometimes the switchgear may be in a basement or on a roof and you have to design it in sections so that you can get it through the existing services.' Co-director Anthony Howarth added, 'Because we have a bespoke product we feel we have to do all of our own sheet metal.
Although systems may look similar there are always small differences that would make it very difficult for someone working with standard cut parts or bought-in frameworks.
If we relied on anyone else's casework we wouldn't be flexible - we give the customer what they want rather than what someone else stocks.' As well as this flexibility, the other factor that allows Howarth Switchgear to offer a premium service is its speed of delivery - and again, the only way to ensure that is to manufacture the critical components in house.
'We are mass producing one-offs, but that is what you have to do.
The Parma might seem quite a big machine for what we do, but the way we see it is that if you can do what the customer wants and react more quickly you will get more work in.
Because we can deliver on time with what the customer wants, they will be able to get the plant up and running sooner.' The LVD Parma punch press offers the speed and flexibility of programming and production that Howarth Switchgear needs.
With a 21-station turret including three direct-drive 50.8mm auto-index stations it gives a wide range of options with a standard tooling setup - and it needs it as Howarth designs and makes around 250 new parts every month.
The Parma 1212 features GE Fanuc 0iP CNC control, and rugged frame and table design to achieve tight tolerances and consistent punching accuracy.
LVD says that it can deliver up to 300 hits/min on 25.4mm centres, and nibble at up to 650 hits/min with a finished part accuracy of +/-0.1mm and +/-0.05mm finished part repeatability.
As Anthony Howarth explained, 'Auto-indexing isn't new technology but it will offer a lot more possibilities, and the programming is much more flexible and faster.
We aren't stubborn and are very prepared to grow into the capabilities of the machine and the software.
One of the things I liked about the Parma was that the punch press and the software came as a package, and the Cadman P 3D software has an unfolding module so that you can flat pack your parts from a 3D file.' The speed and quality of the manufacturing process is extremely important to Howarth's work and cash flow, said Chris Howarth.
'These can be really large installations and a considerable amount of cash (in components) can be tied up on the shop floor.
What we were looking for with the Parma was performance and flexibility at a cost effective price and we are now applying the Parma's advanced technology to speed up our work flow which in turn can only benefit our customers.'
Howarth Switchgear has built its business on providing exactly what customers want when they want it, and to give it the capacity and flexibility to meet these demands it has just invested in a new LVD Parma 1212 CNC punch press. Director Chris Howarth says that the key arguments for the Parma were that it gave a generous specification for a cost-effective price and a short delivery time. He was also convinced it would be reliable, as the company had been running a punch press from LVD's predecessor Shape Machines for the past twenty years with very few problems - and those problems that did occur were fixed very quickly.
'The Shape machine has worked well for us with very few breakdowns, but we thought it was time to move on,' he said.
Howarth's business is building electrical switchgear systems for all kinds of non-domestic premises - from banks and call centres to chemical plants, food processors and military installations.
And even though they try and incorporate standard elements, no two systems are the same.
'Every building is different and the system requirements in buildings are changing all the time,' said Howarth.
'If you are refurbishing a building you are going to need 100 to 150% more power because everything now is IT-oriented.
And if you have more computers you need more air conditioning to deal with the heat they give out.
The result is that they end up trying to get much more switchgear into the same space as they used before.
So it all has to be specially built.
The other problem is that sometimes the switchgear may be in a basement or on a roof and you have to design it in sections so that you can get it through the existing services.' Co-director Anthony Howarth added, 'Because we have a bespoke product we feel we have to do all of our own sheet metal.
Although systems may look similar there are always small differences that would make it very difficult for someone working with standard cut parts or bought-in frameworks.
If we relied on anyone else's casework we wouldn't be flexible - we give the customer what they want rather than what someone else stocks.' As well as this flexibility, the other factor that allows Howarth Switchgear to offer a premium service is its speed of delivery - and again, the only way to ensure that is to manufacture the critical components in house.
'We are mass producing one-offs, but that is what you have to do.
The Parma might seem quite a big machine for what we do, but the way we see it is that if you can do what the customer wants and react more quickly you will get more work in.
Because we can deliver on time with what the customer wants, they will be able to get the plant up and running sooner.' The LVD Parma punch press offers the speed and flexibility of programming and production that Howarth Switchgear needs.
With a 21-station turret including three direct-drive 50.8mm auto-index stations it gives a wide range of options with a standard tooling setup - and it needs it as Howarth designs and makes around 250 new parts every month.
The Parma 1212 features GE Fanuc 0iP CNC control, and rugged frame and table design to achieve tight tolerances and consistent punching accuracy.
LVD says that it can deliver up to 300 hits/min on 25.4mm centres, and nibble at up to 650 hits/min with a finished part accuracy of +/-0.1mm and +/-0.05mm finished part repeatability.
As Anthony Howarth explained, 'Auto-indexing isn't new technology but it will offer a lot more possibilities, and the programming is much more flexible and faster.
We aren't stubborn and are very prepared to grow into the capabilities of the machine and the software.
One of the things I liked about the Parma was that the punch press and the software came as a package, and the Cadman P 3D software has an unfolding module so that you can flat pack your parts from a 3D file.' The speed and quality of the manufacturing process is extremely important to Howarth's work and cash flow, said Chris Howarth.
'These can be really large installations and a considerable amount of cash (in components) can be tied up on the shop floor.
What we were looking for with the Parma was performance and flexibility at a cost effective price and we are now applying the Parma's advanced technology to speed up our work flow which in turn can only benefit our customers.'
Slitting die tooling offers longer regrind life
Slitting die tooling system for CNC punch presses uses a tough and wear-resistant premium tool steel for the slitting die blade to offer twice the regrind life of standard tooling.
The Wilson 2-4-1 Slitting Die system is the latest innovation developed by Wilson Tool. The 2-4-1 Slitting Die system offers twice the regrind life over a standard solid die. The Slitting Die blade is manufactured from Ultima, a premium tool steel which is tough and resistant, excelling in applications which demand long-term wear resistance and toughness.
Ultima can further extend the tool life by up to 400% compared with a standard die, representing considerable cost-savings on replacement tooling.
The special die insert, exclusive to Wilson Tool, is fully supported by the die base which is made of a special shock-absorbent steel designed to resist the repeated impact that can sometimes cause conventional dies to crack.
As the die insert is reground, the shims supplied with the assembly can be used to return the die assembly to the correct height.
When the die insert wears out, a new 2-4-1 insert can be purchased for less than the price of a standard replacement die.
The Wilson 2-4-1 Slitting Die system is the latest innovation developed by Wilson Tool. The 2-4-1 Slitting Die system offers twice the regrind life over a standard solid die. The Slitting Die blade is manufactured from Ultima, a premium tool steel which is tough and resistant, excelling in applications which demand long-term wear resistance and toughness.
Ultima can further extend the tool life by up to 400% compared with a standard die, representing considerable cost-savings on replacement tooling.
The special die insert, exclusive to Wilson Tool, is fully supported by the die base which is made of a special shock-absorbent steel designed to resist the repeated impact that can sometimes cause conventional dies to crack.
As the die insert is reground, the shims supplied with the assembly can be used to return the die assembly to the correct height.
When the die insert wears out, a new 2-4-1 insert can be purchased for less than the price of a standard replacement die.
Tool systems fit punching requirements
Danobat Punch Press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements.
Danobat punch press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements. These include Mate Ultra TEC, Mate Ultra XT, Mate original style thick turret tooling, and the Mate Ultraform forming tool system. Mate Ultra TEC is a full-featured, highest performance thick turret punching system that increases tool performance and flexibility, offers extended tool life, and allows interchangeability with existing systems.
Features of the Ultra TEC system include: premium high speed tool steel, quick tool change, easy click length adjustment (no shims or tooling required), grooved guides for best lubrication, Slug Free Die design, and relieved strippers for extended grind life.
Mate Ultra XT is a new tooling alternative with more features than original style thick turret tooling but not as full-featured as the Ultra Tec line.
Designed to give press operators extra setup convenience, the system is another choice to achieve the highest quality punching at the lowest cost per part.
Ultra XT has these high performance features: premium high speed tool steel, quick tool change, easy click length adjustment, grooved guides for best lubrication and Slug Free Die design.
Mate Original Style Thick Turret Tooling is an economical thick turret tooling system that is fully OEM compatible with design enhancements that include: premium high speed tool steel punches, hexagon shaped 1/2' A and 1-1/4' B station punch heads for easy adjustment and maintenance, and Slug Free Die design.
All three tooling systems are available in sizes for 1/ 2' A station, 1-1/4' B station, 2' C station and 3-1/2' D station.
All Mate Tooling systems are 100 percent unconditionally customer satisfaction guaranteed.
Danobat users can gain a competitive advantage by using exclusive Mate Ultraform special assemblies to expand their fabricating capabilities while eliminating expensive secondary operations.
Examples include the new Mate HexLock system, which provides an alternative to self-clinching fasteners, and the Mate SnapLock assembly, which creates fabricated joints without secondary welding operations.
Danobat punch press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements. These include Mate Ultra TEC, Mate Ultra XT, Mate original style thick turret tooling, and the Mate Ultraform forming tool system. Mate Ultra TEC is a full-featured, highest performance thick turret punching system that increases tool performance and flexibility, offers extended tool life, and allows interchangeability with existing systems.
Features of the Ultra TEC system include: premium high speed tool steel, quick tool change, easy click length adjustment (no shims or tooling required), grooved guides for best lubrication, Slug Free Die design, and relieved strippers for extended grind life.
Mate Ultra XT is a new tooling alternative with more features than original style thick turret tooling but not as full-featured as the Ultra Tec line.
Designed to give press operators extra setup convenience, the system is another choice to achieve the highest quality punching at the lowest cost per part.
Ultra XT has these high performance features: premium high speed tool steel, quick tool change, easy click length adjustment, grooved guides for best lubrication and Slug Free Die design.
Mate Original Style Thick Turret Tooling is an economical thick turret tooling system that is fully OEM compatible with design enhancements that include: premium high speed tool steel punches, hexagon shaped 1/2' A and 1-1/4' B station punch heads for easy adjustment and maintenance, and Slug Free Die design.
All three tooling systems are available in sizes for 1/ 2' A station, 1-1/4' B station, 2' C station and 3-1/2' D station.
All Mate Tooling systems are 100 percent unconditionally customer satisfaction guaranteed.
Danobat users can gain a competitive advantage by using exclusive Mate Ultraform special assemblies to expand their fabricating capabilities while eliminating expensive secondary operations.
Examples include the new Mate HexLock system, which provides an alternative to self-clinching fasteners, and the Mate SnapLock assembly, which creates fabricated joints without secondary welding operations.
CNC punch presses have large turret capacity
Robust, thick turret tooling style CNC punch presses, 200 and 300kN, offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.
LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.
Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.
Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.
A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.
Bridge frame construction provides accuracy and durability.
LVD's latest punch presses handle workpieces up to 1524 x 2500mm depending on model.
Larger workpieces are handled with clamp repositioning.
Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.
* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona's high-speed operation while reducing noise and shock.
Fully programmable stroke profiles and patented Smart Stroke feature maximize punching performance and provide flexibility for punching and forming applications.
Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.
Up to 48-station turret capacity - Verona's large and versatile double-track turret provides flexibility and easy set- up.
Every station accepts shaped punches and dies, reducing set-up time.
A unique mix of turret stations provides exceptional capacity.
Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.
The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.
The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.
Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.
* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.
This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.
The punch press accommodates the latest in tooling technology for high-performance fabricating.
These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.
Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.
Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.
* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.
Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.
* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.
LVD's automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.
Verona may be integrated with a robotic Pick-Sort material handling system.
The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.
The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.
* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.
LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.
Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.
Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.
A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.
Bridge frame construction provides accuracy and durability.
LVD's latest punch presses handle workpieces up to 1524 x 2500mm depending on model.
Larger workpieces are handled with clamp repositioning.
Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.
* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona's high-speed operation while reducing noise and shock.
Fully programmable stroke profiles and patented Smart Stroke feature maximize punching performance and provide flexibility for punching and forming applications.
Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.
Up to 48-station turret capacity - Verona's large and versatile double-track turret provides flexibility and easy set- up.
Every station accepts shaped punches and dies, reducing set-up time.
A unique mix of turret stations provides exceptional capacity.
Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.
The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.
The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.
Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.
* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.
This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.
The punch press accommodates the latest in tooling technology for high-performance fabricating.
These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.
Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.
Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.
* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.
Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.
* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.
LVD's automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.
Verona may be integrated with a robotic Pick-Sort material handling system.
The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.
The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.
* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.
Convert power press into flexible punching
A CNC punching tool converts an existing mechanical power press into a 2-axis high capacity flexible punching unit by adding a numerically controlled roll feeder and traverse slide.
Shear-Form Machine Tools, Coventry based sheet metal and plate working machinery supplier and the sole UK representative for Dimeco Groupe, the French coil processing equipment manufacturer has launched 'Decopunch' a new CNC punching tool that converts an existing mechanical power press into a 2-axis 'Flexipunch' high capacity punching unit by adding a numerically controlled roll feeder and traverse slide. The slide is used to move a removable cassette, which is fitted with cartridge tooling, actuated by built in selectors. It is suitable for manufacturing punched or embossed components without any limitation on length and up to 800mm wide, such as cable trays, storage racks and computer racks as well as Z and C purlins and building structures.
It can also be used for nesting and stamping circular components producing up to 10% savings in material costs.
Features of 'Decopunch' include flexibility with components with the same width but different lengths being produced in a row one after each other, thereby reducing down times.
It can be adapted to fit to 'C' frame or straight sided presses, whilst the tooling cassette can hold up to 12 cartridge tools and be change in less than 3 min.
The Siemens servomotor with its twin pitch control system produces a +/-0.1mm component length accuracy.
Dimeco's user friendly Simostar 12in graphic touch screen control terminal supplies the operator with manufacturing data such as parameterised product lists, maintenance requirements and instruction manuals, whilst production programs can be prepared offline using the installed software.
Shear-Form Machine Tools, Coventry based sheet metal and plate working machinery supplier and the sole UK representative for Dimeco Groupe, the French coil processing equipment manufacturer has launched 'Decopunch' a new CNC punching tool that converts an existing mechanical power press into a 2-axis 'Flexipunch' high capacity punching unit by adding a numerically controlled roll feeder and traverse slide. The slide is used to move a removable cassette, which is fitted with cartridge tooling, actuated by built in selectors. It is suitable for manufacturing punched or embossed components without any limitation on length and up to 800mm wide, such as cable trays, storage racks and computer racks as well as Z and C purlins and building structures.
It can also be used for nesting and stamping circular components producing up to 10% savings in material costs.
Features of 'Decopunch' include flexibility with components with the same width but different lengths being produced in a row one after each other, thereby reducing down times.
It can be adapted to fit to 'C' frame or straight sided presses, whilst the tooling cassette can hold up to 12 cartridge tools and be change in less than 3 min.
The Siemens servomotor with its twin pitch control system produces a +/-0.1mm component length accuracy.
Dimeco's user friendly Simostar 12in graphic touch screen control terminal supplies the operator with manufacturing data such as parameterised product lists, maintenance requirements and instruction manuals, whilst production programs can be prepared offline using the installed software.
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