Slat cleaner removes flatbed laser slag build-up

A new award-winning product from Trumpf’s Power Tool Division was shown for the first time in the UK at MACH 2006. The TSC-1 slat cleaner provides an easy method of removing the slag that builds-up during laser processing from support slats and pallets of the flatbed machine. It saves time, costs and enhances workpiece finish.

The TSC-1 is a first.

There is no other dedicated cleaning tool for this purpose and Trumpf’s innovation in this regard has resulted in it receiving the coveted 2006 UK German government Award for ‘Outstanding Innovative Achievement’.

The TSC-1 underwent rigorous assessment before being declared the winner by the Munich and Upper Bavarian Chamber of Trade.

Until now, dirty pallets either had to be replaced or manually pounded with a hammer to remove the slag build-up.

It was a process that was time-consuming, not wholly effective and certainly not beneficial to the operator’s health.

With the new TSC-1 it takes just 20 min to clean a standard slat measuring 1500mm x 3000mm.

Water jet glass cutting is quiet, easy to use

In the design and construction of modern automotive vehicles such as passenger cars, buses, coaches and goods transporters, the need to integrate large sheets of glass requiring intricate, often complex cut-out areas, has presented manufacturers with problems both technical and expensive in time and money. Now a breakthrough has been established by the leading Polish automotive glass supplier Saint-Gobain Sekurit HanGlas Polska, who have found that the installation of a high-accuracy Water Jet Sweden cutting machine at their Zary Plant has enabled them to cut-out any size or shape of area easily and economically. * Traditional method - traditionally, automotive safety glass is cut to size by first using automated profiling machines with diamond wheels to slit or score the surface for subsequent snapping off by skilled workers.

Straight-line work is easy, but contours and geometric shapes call for greater skills.

It has also long been possible to make holes in glass of reasonable diameters.

What has not been so practical, until now, has been the ability to produce internal cut-outs of any desired size or complexity.

The breakthrough has come about with the advent of water jet cutting equipment.

* Simple solutions - the Zary plant took delivery of the WJS NC3020S machine 18 months ago and technical director Marek Sulik with Wojciech Lipinski’s project development team immediately set about making the process suitable for their particular needs.

Glass, by its very nature, shows up any defects that would probably not be evident no matter if present in other materials and so surface finish is of the utmost importance.

It was found, for example, that the conventional knife-edge ‘wave formation’ table normally recommended for use on the machine caused ‘ricochet’ marks on the underside of the glass and so a lot of thought and energy was put into finding an alternative means of support for the glass while being cut.

A highly-satisfactory solution was found that appeared delightfully simple in retrospect.

The table-top is positioned below the water level, but the glass sheets are supported well above it by a large number of freely positioned spacers in the form of rubber collars mounted on top of large-diameter plastic tubes.

This simple idea was immediately successful as it is now possible to quickly position the supports clear of the cutting path for any desired profile with the result that products are totally unmarked every time.

* Computer control - at a more detailed level, the development team naturally devoted much time to establishing the optimum combination of dynamic values for the various operating parameters of the abrasive water jet equipment.

These included: nozzle diameter, jet pressure (up to 4,000 bar) and rate of ramping it up, grit size (120 mesh garnet), traversing speed, including acceleration/ deceleration, and positioning.

In establishing most of these, the GE Fanuc 160i MB NC computer control system fitted was found to be extremely effective and, although it being the first controller from this supplier to be used at Zary.

Project engineer, Rutkowski, says it has been easy to program and, like the WJS machine itself, has been highly reliable.

The control panel is conveniently mounted on a swing-arm at one corner of the machine and is linked to the company’s CAD/CAM facility, so that programs for any of the many parts to be produced can be called up instantly - important where jobs are for short runs and are ordered on a JIT basis from all over Europe.

* Fast, easy and environmentally friendly - in operation, the WJS machine was found to be clean, quiet and easy to use.

After the operator has lifted a sheet of glass from the vertical storage rack, located by the workstation, with the aid of its vacuum lift cradle, it is rotated to the horizontal plane and laid on the table against the positioning stops.

This takes just a few seconds and is all that is needed to be ready to cut.

The water jet cutting machine is then switched on and will run entirely automatically as it cuts the desired internal profile(s) in the glass.

Generally the tinted glass sheets involved are up to 2200 x 1900mm in size, well within the machine’s 3.0 x 2.0m capacity, and the glass sheets may be as thick as required.

In a direct comparison with a situation where the production of windows with internal ‘holes’ was previously possible, the water jet cutting method enabled productivity to be increased by more than 300%, from 3 to 10/h.

Using the water jet system, both cut-outs and holes can be performed in a single setting without the need to transfer to a drilling machine.

* WJS accuracy attracts new business - as well as offering increased scope to designers for incorporating distinctive internal hole shapes within sheet glass, the system can also do things not possible by any other means.

For example, one designer wanted a pattern of 78 holes of 6mm diameter to be incorporated but such small holes (very close to each other) could not be drilled.

Thanks to the extremely small radii that the WJS machine can perform and its 0.1mm tolerance capability, the work could be taken on at Saint-Gobain Sekurit HanGlas Polska and, in fact, many jobs will now find their way to Zary because radii of less than 5mm are required.

Reasons for seeking internal cut-outs in vehicle glass, apart from the obvious ones of needing to position integral door handles, window latches etc, can be for enabling structural elements to pass through, for entire rear light clusters to be mounted in a back window, fuel pipe access and so on.

Ultra-high pressure waterjet systems

Jet Edge, a leading manufacturer of ultra-high pressure waterjet systems, will demonstrate its latest waterjet cutting technology at the Experimental Aviation Association’s Oshkosh AirVenture, at Wittman Regional Airport in Oshkosh, Wis. During AirVenture, Jet Edge sales engineers will showcase the remarkable versatility of waterjet and abrasive waterjet cutting and discuss their many applications in the aviation industry. Jet Edge also will introduce special guest, Pilot Dave Willcock of St Catharine’s, Ontario.

Willcock has built a successful business manufacturing aircraft parts with a Jet Edge system.

His business, Profile Waterjet Cutting, has been featured in Canadian MetalWorking and Canadian Industrial Machinery.

Waterjet cutting is ideal for making aviation parts, Willcock said, noting that aircraft are a compilation of flat, thin parts.

He read a lengthy list of parts he had made for just one customer.

It included 22 items ranging from gussets and flanges to power distribution panels and custom wine racks.

‘There are hundreds or even thousands of parts,’ he said.

‘The number of parts you can make will just stagger you.’ Willcock, who owns 10 aircraft, contends that home-built aviation enthusiasts could greatly increase their productivity by using waterjet instead of conventional cutting tools.

‘Most of the stuff is made with bandsaws, hacksaws and files,’ he said.

‘If you were building an aircraft from scratch, you would save months of work in constructing a project.’ Aircraft enthusiasts also could save money by making their own specialty tools at a fraction of their retail cost, Willcock added.

Flexibility, productivity and lights out running

E and R Moffat is one of the largest UK-based designers and manufacturers of commercial catering equipment. The company’s stainless steel products for the preparation, display and serving of food can be found in schools, hospitals, cruise ships, oil rigs and gourmet restaurants the world over. Although it still appreciates the value of craft skills for certain aspects of its production, it has not been slow to invest in advanced technology and purchased a Trumpf L3030 laser system with LiftMaster automatic sheet handling.

The Trumpf system not only provides flexibility, productivity and lights out running, but running costs for high speed cutting are slashed by using compressed shop air instead of high pressure nitrogen.

As R and D Technician Scott Hamilton explains, ‘We do a lot of one-off bespoke equipment such as ranges and serveries where the architect or chef will specify exactly the layout they want - so you can end up with some quite fancy cut shapes.

We have Cat Eye on it as well which means we can put a sheet back on and make further modifications if the customer decides to change their specification.’ Before the laser was installed this work was done on a Trumpf TC500 punch press, and as Scott says, using tool rotation they could cut almost anything on the TC500 that they can on the laser, but on the type of work they are doing the laser is much quicker.

‘The speed is unbelievable,’ says Scott.

‘The normal thickness for our stainless counter tops is 2mm and with normal shop compressed air we can cut this at around 12 to 13 metres per minute.

On lighter gauge material - and we go down to 0.9mm - we are cutting at up to 28 metres per minute.

‘When you cut with shop compressed air you get a gold finish on the edge rather than the conventional edge you get with high pressure nitrogen.

These edges are perfectly acceptable for welding without any further preparation, but most of our edges are turned under anyway, and once they are hidden it doesn’t matter.’ What does matter though are the cost savings.

Production cell based laser technology

Remaining competitive whilst improving quality and expanding capability is a challenge that all ambitious companies face. Propbrook, one the UK’s leading privately owned elevator engineering companies is no exception. It firmly believes that continued investment in production cell based laser technology is the future for its type of work, giving it the edge on finish and unit cost.

Propbrook has always invested in high technology manufacturing to ensure that improvements in quality and productivity go hand in hand.

It was the first UK customer for TRUMPF’s TC2020R punch press and also for the L2510 2D laser cutting machine.

Although punching still has an important role at Propbrook, the company’s commitment to laser technology is clear.

Its latest acquisition, TRUMPF’s L2510, complements established L2503 and L3030 machines ‘We are very much involved in bespoke marketing,’ explains Chairman David Yates.

‘Batch sizes range considerably.

We work in anything from 20 gauge to 12mm, producing small parts through to panels in mild steel and stainless.

So we need the versatility of laser to respond quickly to the needs of our customers.’ Lights out production is the aim for Propbrook now.

‘The longstanding support relationship we have with TRUMPF and the build quality of its machines are important factors here,’ David Yates continues.

Servo-controlled high speed press brake

LVD will display a PPEB servo-controlled press brake featuring the Easy-Form Laser adaptive bending system and high-speed turbo package at MACH2006, Hall 4, stand 4665. The PPEB-EFL Turbo 80/25 - 80 Tonne by 2.5 metre model will be exhibited. In process Advanced Angle Measurement with Easy-Form Laser The PPEB press brake displayed at MACH2006 will feature LVD’s Easy-Form Laser adaptive bending technology.

Easy-Form Laser is a unique angle measurement device that uses a laser to monitor and correct the angle in real time during the bending process, producing accurate bending results from the first piece.

Easy-Form Laser uses symmetrical measurement at the front and back of the die to determine the exact value of the angle of the workpiece.

The system projects straight lines composed of multiple light points onto the workpiece and the vertical part of the die, providing a measurement calculation every 20 milliseconds.

The sensing device transmits information in real time to the CNC control unit, which processes it and subsequently recalculates the correct depth adjustment to obtain the correct angle.

The bending process is not interrupted, and no production time is lost.

Unlike mechanical angle control systems, Easy-Form Laser does not extend the cycle duration and provides accurate results consistently.

It does not require calibration after each set-up.

High-speed Turbo The press brake displayed at MACH2006 will be equipped with a high-speed turbo hydraulic system, which is now available on PPEB press brakes up to 350 tons.

The turbo system increases the approach, pressing and return speeds of the press brake ram by as much as 30 percent compared to standard machines of the same size and type.

Increasing the operating speed of larger capacity press brakes improves flexibility and provides the ability to produce parts that would typically be assigned to smaller machines with higher performance.

Faster pressing speeds improve the output of higher tonnage press brakes particularly when using wide dies that require deeper penetration of the punch and longer ram travel.

LVD’s PPEB series of precision press brakes are equipped with state-of-the-art hydraulics and electronics and are offered in multi-axis configurations.

PPEB press brakes are built on a rigid frame design to ensure accuracy.

PPEB press brakes are available in working lengths from 1.5 to 15 m with tonnages up to 3000 tons.

Powerful CADMAN CNC Control and Software All PPEB press brakes feature the exclusive CADMAN control.

CADMAN is a powerful PC-based control complete with Windows operating system and the CADMAN-B 3D programming software.

The high quality design of the press brake coupled with the CADMAN control help ensure the consistency of the bend over the entire part length.

The CADMAN control, equipped with an Intel Pentium microprocessor and a 2-gigabyte hard drive, creates and stores interactive databases for bend allowance, angle corrections and spring-back.

These user-generated databases, created by actual bending results, are searched and applied each time a part program is generated.

This automatic optimization of the part program eliminates trial bending, and reduces the time required to produce a quality part.

CADMAN-B 3D software is standard in the machine control and is available as an offline programming system.

The databases developed and maintained in the PPEB press brake can be duplicated and downloaded to the offline system.

Having actual bending technologies available prior to part creation eliminates unwanted errors in the actual blank generation prior to bending, and assures accurate part tolerances throughout the process.

The LVD group based in Gullegem - Belgium is a leading worldwide designer, manufacturer and distributor of a comprehensive range of sheet metal / plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotines and automated flexible manufacturing systems - all supported by its’ CADMAN PC-based, Windows compatible programming system for punching, laser cutting and bending.

5kW linear CNC laser cutting machine

Being shown for the very first time in the UK LVD will introduce the Axel 3015S 5Kw Linear CNC laser cutting machine at MACH2006, Hall 4, Stand 4665. The Axel 3015S 5kw Linear provides advanced laser cutting capabilities and high-speed part processing combined with integrated automation to maximize machine productivity and facilitate unattended operation. The laser cutting machine incorporates the most recent advancements in linear drive technology, laser power and control systems to provide superior cutting capabilities, greater flexibility and ease of use.

The Axel 3015 S offers optimum performance when processing both thin sheets and thick materials.

A high pressure (clean cut) cutting head is available for 5′, 7.5′ or 10′ cutting lens.

The high-pressure cutting head produces exceptionally clean cuts and is equipped with a safety system that protects the head from collision with the workpiece The Axel 3015 S on display at MACH2006 will feature a 5 kW laser source.

The high beam quality of the 5 kW laser allows processing of thin material at extremely high speeds up to 40 metres/min in 1.0mm material and thick material with high quality surface finishes.

A new 10′ cutting lens allows the Axel to process thick mild steel10 mm to 15 mm,10 to 15 percent faster.

The 10′ lens permits processing of 25 mm mild steel with a 4 kW laser source.

Using the 10′ lens, 20 mm mild steel can be processed at 1000 mm/min, 10 mm mild steel can be cut at speeds of 2000 mm/min.

The laser source, CNC and servomotors are integrated and interfaced as a complete system to optimize machine performance, offering high speed and reliability, low operating and maintenance costs.

The monoframe design incorporates high precision hardened guideways and optimal driving system to achieve high-speed acceleration and positioning speeds.

The Axel 3015 S boasts an improved frame design with increased stiffness.

The rigid frame construction minimizes deformation caused by high acceleration, improving overall machine accuracy.

LVD’s Axel 3015 S features a constant beam length system that keeps the diameter of the laser beam constant and consequently always maintains a fixed focal point position.

This results in higher cutting speeds and superior cut quality maintained over the entire working area.

The Axel 3015 S is now available with LVD’s exclusive Win-Executor software.

The software further simplifies machine use by providing an explanation of error messages, automatic calculation of stand off distance, and graphic display during the cutting process.

The Axel laser system combines high-speed part processing with integrated shuttle tables for continuous, uninterrupted part processing.

The shuttle table design allows one table to be loaded while the machine is cutting on the other table, maximizing uptime.

The Axel 3015 S features a newly redesigned shuttle table drive system with double-driven timing belt for improved machine performance and reliability.

Table change time is now three times faster and is completed in 15 seconds.

Shuttle tables are driven by a coupled toothed belt, which also provides faster and smoother pallet changing.

The laser system’s working area is enclosed with a protective plexiglass cabin that provides a clear view of the cutting process.

The manually operated rotating door also allows easy access for machine maintenance.

The LVD group based in Gullegem - Belgium is a leading worldwide designer, manufacturer and distributor of a comprehensive range of sheet metal / plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotines and automated flexible manufacturing systems - all supported by its’ CADMAN PC-based, Windows compatible programming system for punching, laser cutting and bending.

CNC turret punch press with automated load

Being shown for the very first time in the UK LVD will introduce its high speed, high productivity Global 20 1225, a 200 kN CNC turret punch press, with Automated Load - Pick and Sort System at MACH 2006, Hall 4, stand 4665. The Global 20 1225 is part of LVD’s Global 20 series of high performance turret punch presses. The machine combines high production technologies to address the fabricating requirements of job shops and O.E.M.s around the world.

Its unique contemporary design provides a rigid base for precision punching.

Key features include large sheet processing capability, a 30-station turret with large auto-index capacity, and state-of-the-art GE Fanuc CNC control.

The Global 1225 on display at MACH2006 will feature a Robot Automated Load and Pick-Sort system for fast, cost effective cut-part unloading.

The robotic system handles cut part dimensions up to 1000 x 2000 mm with an unload time of 12 seconds per part.

The Global 1225 processes workpieces up to 2500 x 1250 mm.

Working area capacity with one repositioning is 5000 x 1250 mm.

The punch press has an advanced hydraulic press drive optimized for high-speed operation.

This high-speed hydraulic system delivers up to 400 hits per minute on 25 mm centers and is capable of producing at 1000 strokes per minute in continuous nibbling mode.

The hydraulic ram also offers the flexibility of electronic adjustments and features that take advantage of the intuitive control interaction.

Users can apply custom settings or alterations to stroke elements such as depth offset, dwell and ram speed, to further maximize machine capabilities.

Fully programmable stroke profiles and the exclusive Smart Stroke feature also maximize punching performance and provide flexibility for punching and forming applications.

Smart Stroke maximizes the productivity of the Global 1225 without operator or programmer intervention.

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes.

The Global 20 1225 features a 30-station turret with station-to-station tool change in less than 1 second.

Replaceable, hardened steel guide bushings eliminate turret tool bore wear.

The turret punch press is available with up to four dia 88.9 mm auto-index stations.

Three auto-index stations are standard with the machine.

Turret capacity can be further increased with the addition of 3- or 8-station indexable Multi-Tools to expand the number of auto-indexable tools.

Full Wheel tool capabilities (cutting and forming) together with thread tapping also expand turret flexibility.

The Global 20 1225 is equipped with three programmable, relocatable work clamps, which can be programmed to a position on the X carriage and individually relocated to a new position within the part program.

Applications for the water-jet cutting process

Flexible water-jet cutting technology can be used in practically all sectors of industry - an article by Peter Longman, Area Manager, KMT Waterjet Systems. The aerospace, building and construction, mechanical engineering, glass industry, wood, textiles and paper manufacturing sectors are all taking advantage of this versatile process. In addition, the automotive and its supplier industries, as well as the electrical, electronic and food processing and defence industries have all emerged as markets for some of the more novel applications of water-jet.

High-speed prototyping and flexible, just-in-time production are well suited to water-jet whilst new applications including cleaning, recycling and decommissioning.

Unlike traditional thermal cutting methods, water-jet cutting technology has major advantages in terms of its high level of cost-effectiveness and flexibility.

The most diverse materials can be quickly and precisely worked using a high-pressure jet of water.

Material thicknesses of 150 mm or more present no difficulties for this cutting processes.

The water-jet achieves optimum cut-edge qualities on both simple and extremely complex contours.

Water- jet cutting falls into general 2D and 3D applications.

2D include the cutting of sheet metal such as: stainless steel, carbon steel, high-alloy nickel steels, aluminium, titanium and copper.

Construction materials include decorative stone, marble, granite, tiles, plasterboard, glass and mineral wool.

Glass covers: laminated glass, safety glass, and bulletproof glass.

Foodstuffs can range from baked goods to deep-frozen products and fish.

Paper, cardboard, corrugated cardboard, printing papers together with miscellaneous materials such as: plywood, leather, textiles, composites, rubber, plastics, sealing materials and foams are also typical 2D applications.

3D and robot applications cover abrasive cutting of titanium, aluminium and stainless steel motor-vehicle components; turbine blades, decorative stone or marble.

Pure water cutting can be used for motor-vehicle components such as carpets, door-trims, fenders, dashboards, instrument panels, rear shelves.

The essential benefits of the water-jet cutting system are the fact that there are no heat-affected zones, no thermal hardening and no material stresses.

From a health and safety point of view there are also no gases and no production of dust or fumes.

Production benefits include the fact that there is no need to sharpen tools whilst high cutting speeds.

high cutting accuracy and high surface quality can be achieved.

Secondary operations such as deburring can be omitted and re-working becomes unnecessary.

Burr-free cut edges, a narrow cutting gap and low tangential forces exerted on the component also provide user benefits.

Waterjet can be used for both cleaning and removing layers of materials from the surface of products.

KMT’s Streamline pump range can provide high pressure to the Rotojet nozzle so that cleaning can be undertaken in an environmentally friendly way without any gases.

The base material’s integrity is not affected and the process is therefore ideally suited to applications such as jet engine turbine blade decontamination.

As part of the restoration and repair of gas turbine jet engine components undertaken by Wood Group Component Repair, coatings need to be stripped from turbine components prior to re-application.

In order to refine the coating removal process, Wood Group is currently carrying out development work using a KMT waterjet system.

This significantly speeds up the process without affecting the base material.

Hundreds of different coatings are applied to the turbine component parts by plasma arc deposition - mainly on to casings and seal areas where the ceramic or other coating is intended to wear in preference to the mating part.

At present the plasma sprayed coatings are removed by conventional machining, acid bath and grit blasting.

This is a very time consuming operation and some of the base material is removed during the operation.

These problems are eliminated by the waterjet process comprising of a Streamline SL IV 50Hp pump that produces 3,800bar (55,000psi) working pressure.