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Artificial Intelligence In Bending

Artificial Intelligence In Bending

Manufacturers are now adopting artificial intelligence (AI) to further create value for the customers. But how would AI be applied to sheet metal bending? In this article, Melvin Tham, Regional Technology Expert – Bending, for TRUMPF, explains.

Using conventional press brakes to achieve high accuracy for sheet metal is challenging due mainly to the property of the material, where its elasticity varies according to its composition and grain direction. Therefore, the process would usually take a longer time as it requires more knowledge and skill in order to achieve higher accuracy.

In today’s industrial environment, machines are loaded with functions to ensure that the manufactured parts are precise and consistent with minimal human/operator intervention, and manufacturers are now adopting artificial intelligence (AI) to further create value for the customers. But how would AI be applied to sheet metal bending?

Automatic Set Up

Given the current high-mix, low-volume market demand, the system must be easily set up within minutes to cater for a job change over. Therefore, a self-centring tooling system would be most ideal. With an automatic tool changer, there is no longer a need for alignment as the tools are automatically placed in position and integrated into the machine. It has three to four times more storage capacity than the machine’s bending length, all just to ensure a quick changeover and without the hassle of tool shortage.

Positioning and Angle Accuracy of Part

Since the bending process is now automatic, the quality of the parts has to be checked automatically as well. Such system would require high dynamic functions such as the backgauge. The backgauge with an axis tolerance of ±0.02 mm and the angle sensor tool with tolerance at ±0.5 deg are required to ensure that the part is placed accurately in position and angle tolerance is achieved by an angle checking device.

Sensors of the backagauge are necessary for the identification of the part in position. Without this, the part would not be able to achieve its desired flange length.

An automatic detection of the angle needs to be equipped to determine the correct angle to be achieved for each bend. With Automatic Controlled Bending (ACB), the total completion time to bend, calculate and adjust will take less than a second!

Identification of Parts and Positioning Compensation

The system must be able to detect the correct part to pick up and automatically determine the datum point to compensate positioning error. It is important to define the datum point so that all bending sequence and positioning accuracy can be referenced.

Although a structured stand that pre-fixed the part datum point can be achieved, the best possible solution will be with a high-resolution and precise camera profile detection that is flexible and automatic. This camera device could detect the sheet stack, height and fine profile of the part for single sheet without the need to specifically prepare sheet in a fixed position. With such function, a lot of time is saved from the preparation for defining, picking and loading of parts.

Gripper Technology

The grippers picking up the parts are of critical importance as well. Our grippers are designed with the concept of holding the parts as firmly as a human hand would. The gripper can be used for multiple parts and the suction cups can be pneumatically turned on or off to cater to different profiles and gripping area.

CAM-assisted Offline Programming

Software plays a very important role in automation. It should be able to strategically control all movement offline with intuitive graphical teaching.

In the past, robot movements are codings that are entered line by line in order to perfect a smooth travel path. With advanced software like TruTops Bend Automation, not only are we are able to graphically teach the movement from one point to another, we can also teach the robot to flip, load and unload the part. The software enables us to run a simulation prior to the actual process.

Robotic Movement and Payload

There are many robotic equipment in the market, with some having more than eight axis of movement and payload of more than 1,000 kg! So how do we know which is suitable?

In bending, it is always the working area within the press brake and robotic system. The bigger the working capacity means there is a better flexibility on the type of profile that can be bent.

The longer the trackway of the robot arm, the more parts can be prepared for loading and unloading. This is to ensure that the machine is always filled with part for continuous production and not idling or waiting for parts. There are also possibilities that the finish part can be stacked in cage or drop box.

The higher the payload means a bigger robot arm would be required. When the arm gets too big, there is a minimum distance of limitation due to the kinetic movement, therefore small parts cannot be picked up. Hence, it is important to define the size of the product before the selection of the automatic bending cell. This will make it easier to select the type of press brake and robotic arm for the job.

With all the necessary functions that are in place to ensure the output quality of the parts, the production is all ready for artificial intelligence bending!

 

For other exclusive articles, visit www.equipment-news.com.

 

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Bystronic Partners With Kurago For Smart Production Management Innovation

Bystronic Partners with Kurago for Smart Production Management Innovation

To develop pioneering process solutions that will drive forward the vision of a smart factory environment, Bystronic is now working with software specialist Kurago within the framework of an innovation partnership. In this venture, Bystronic will be able to rely on Kurago as a strong partner with extensive know-how in the field of consulting and software development for smart production management.

The demand for automation and digital process solutions is increasing across the complete field of sheet metal processing. This trend is having a major impact on our customers’ business models and strategies. The sheet metal processing world will face a fundamental change in the near future and software will play a key role in this transformation. Digital solutions will support users with the planning, interlinking, monitoring, and optimization of all their production processes. All this will boost the sheet metal processing industry to new levels of productivity and transparency.

By joining forces, Bystronic and Kurago will be able to fast-track solutions to make a powerful vision come true very soon.

The first important step of this partnership will be the development of a brand new enterprise operational environment for the sheet metal processing sector, where all the processes relating to the day-to-day business of customers will take place, enabling them to achieve operational excellence and gain a competitive edge. Cloud technology will enable customers to expand Bystronic solution as their company grows, thus reducing the total cost of ownership (TCO). In addition, this solution will allow tech companies of all sizes to develop and offer new products and applications designed specifically for the sheet metal processing sector.

Together with Bystronic, Spain-based Kurago will conceive, create, promote, and implement software that will optimize the manufacturing of metal parts. As a centre of excellence for software, Kurago will develop manufacturing systems that will make the smart factory vision a reality and guide and structure sheet metal processing throughout the entire value chain—with all types of machines from any manufacturer.

“We are convinced that this partnership will allow Bystronic and Kurago to pool their expertise and energy in order to achieve a sustainable impact on the future trends and demands in the sheet metal processing industry. Our shared goal is to offer our customers pioneering solutions that drive them forward on the path towards a digitally extended manufacturing environment,” said Alex Waser, CEO of the Bystronic Group.

Jesús Martínez, CEO of Kurago, said, “We are grateful and delighted to be able to seize this opportunity to make the digital factory come true together with Bystronic, an innovation leader in the sheet metal processing sector. The enterprise operational environment we will develop will constitute an open space where many market players, who currently still view each other as competitors, will start cooperating. This environment will be a fully digital ecosystem, which is the only way we can make this revolution a reality. Cloud computing enhances the capabilities of all players and levels the playing field, opening up the same opportunities to everyone, while also preserving the differences and competitive advantages that make each of them the best choice for their own customers. This will benefit all Bystronic customers around the globe.”

 

Further reading:

Bystronic To Complete Modernisation Of Production Facility

Bystronic On Flexible Automation

Bystronic Releases BySmart Fiber In 4020 Format

Bystronic Releases Entry Level Solution For Bending

Bystronic Expands Portfolio Of XXL Laser Cutting System

 

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The Metal Machining Versatility Of Abrasive Waterjets

The Metal Machining Versatility of Abrasive Waterjets

In today’s dynamic manufacturing world, flexibility and versatility is the name of the game. Those shops that adapt and succeed are those that have moved beyond a single-purpose machinery mentality and embraced highly versatile multi-purpose technologies. Article by Joshua Swainston, OMAX Corp.

Innovation dictates how and what we machine. Steel and aluminum are standards, but new alloys are changing how we construct everything, from key rings to airplanes. On top of this, customer demands continue to change. When they do, your machine shop must adapt and change as well.

In today’s dynamic manufacturing world, flexibility is the name of the game, and those shops that adapt and succeed are those that have moved beyond a single-purpose machinery mentality and embraced highly versatile multi-purpose technology such as abrasive waterjet cutting.

Abrasive waterjet is a method of material cutting using a high-pressure stream of water to erode a narrow cut in the part stock material. To cut a wider range of materials from tool steel to titanium to foam, a granular (typically garnet) abrasive is added to the waterjet, increasing its cutting power.

Waterjet manufactures, such as OMAX Corp., often offer an array of additional features and specialized software that further enhance waterjet machining with such capabilities as beveled cutting and taper compensation, among others. With the versatility of an abrasive waterjet, you and your shop are ready for whatever part material changes may happen in the future.

Figure 2: Waterjets come in an array of sizes to meet your shop’s needs and capabilities.

Controlling workflows and costs

Most machine shops will tell you cost control and short turnaround times are the most important aspects to running a profitable operation. One of the major reasons a shop decides to purchase an abrasive waterjet is to bring advanced cutting capabilities in house, which has the potential to pay huge dividends. Outsourcing metal cutting and near netting eats into turn-around times and profit margins. By having a waterjet on your own shop floor, you control your workflow and costs, and no other shop knows this better than Titan Boats in Vancouver, Canada.

Titan Boats was spending time and money outsourcing its waterjet cutting, and according to Jennifer Michell, Organization Development Manager for Titan Boats, the reason was logistics. “Living on Vancouver Island means that the proximity to a waterjet machine that would meet the size requirements of our vessels, would have to be done off island,” she explained. “With that bears shipping costs and lead time waits. We wanted to eliminate those added expenses by the purchase of our waterjet.”

By adding its own abrasive waterjet, the shop was able to streamline its workflow and cut production times from several weeks to a few days.

In terms of types of material cut, an abrasive waterjet is the most versatile cutting method available. Where EDM specifically cuts electrically conductive materials, and laser is limited to thin, non-reflective metals, abrasive waterjet cuts virtually every metal on the market. Abrasive waterjet machines cut steel, aluminum, brass, copper, titanium, Inconel, chromel, cupronickel, and basically every other type of metal.

In particular, abrasive waterjet is excellent at cutting titanium (over other methods of manufacturing) as the jetstream of the waterjet never dulls, eliminating the need for time-consuming tool changes. Cutting metal on an abrasive waterjet is particularly attractive as the cut product has no heat affected zones (HAZ) or material distortion, often removing the need for secondary machining.

Versatility and accuracy

Venable Machine Works is another shop that now benefits from abrasive waterjet cutting for its part production operations. The Saskatoon, Canada, shop bought its OMAX 55100 in 2011, and Dan Wingerak, Venable’s machine shop foreman, explains his thinking when purchasing a waterjet. “When deciding between a flame, plasma, laser, or waterjet, we decided to go with the waterjet due to the precise cutting, option with no heat or heat affected distortion, and the ability to cut almost any type of material,” he said.

Lasers are typically extremely expensive and require extensive training for operators. Plasma can produce noxious fumes (depending on the material cut) and leave a rough-cut surface. For a machine shop weighing its machine tool options, a waterjet is a relatively inexpensive, clean and useful alternative.

In addition to its versatility in materials, abrasive waterjet handles the full spectrum of part sizes. For instance, abrasive waterjet is pushing the extremes when it comes to micro and macro machining. Used in medical, national defense, and circuitry applications, the MicroMAX JetMachining Center from OMAX, for example, is capable of a positioning accuracy within five microns. On the larger side, the OMAX 120X series, offered with a customizable cutting bed that can reach up to 40 feet by 10 feet, is being used in large tank fabrication as well as architectural metal and glass. The size of the finished product is only limited by the size of the waterjet’s cutting table, allowing a manufacturer to work as small or as large as needed without additional specialty equipment.

For K&W Tool from Michigan in the United States, the durability of its two abrasive waterjet machines is a huge benefit for the contract fabrication shop. “We use both of our OMAX 120X waterjets at least ten hours a day; if we are busy, we run them both 24/7,” said Camren Kring, Project Manager at K&W. “The ease of use and low maintenance associated with abrasive waterjet make them nearly capable of non-stop machining.”

K&W also added the OMAX A-jet accessory to its waterjets. With a cutting range from 0° to 60°, the A-Jet can easily cut beveled edges, angled sides, and countersinks. Advanced features in OMAX’s IntelliMAX Software Suite allow the A-Jet to compensate for taper and easily create complex 3D shapes. The A-Jet is a completely software-controlled multi-axis cutting head that greatly expands K&W’s versatility.

Software matters

The versatility of an abrasive waterjet is only as good as its software. Using underperforming software with an off-brand waterjet will result in off-spec parts. On the other hand, using software programmed with the unique characteristics of the waterjet in mind, coupled with a superior machine, results in excellent machining.

OMAX has made its software easy to use. With OMAX’s IntelliMAX software, the operator enters the material type and thickness, then the software calculates and controls the cutting. The machinability is already factored into the software. If an operator entered in a new design into the IntelliMAX MAKE program—the program that controls the waterjet—for instance, they will be prompted by a screen with a dropdown list of various material types. This dropdown list contains over 60 different materials ranging from red oak to Inconel to PVC and everything in between. Additional materials can be entered in manually, and after an operator enters the material and thickness, they are ready to cut. At any time, an operator can reset the material by a simple click of a button.

With the development of its ProtoMAX, OMAX incorporated all the versatility benefits of large abrasive waterjet cutters into a sleek and economical small abrasive waterjet that is perfect for job shops, engineering classrooms, makerspaces, personal use, and people like Dan Dumphy.

Dumphy started his own business, Dumphy Cycle Machining, in 2018 with the aid of the ProtoMAX, the first personal waterjet on the market.

What convinced Dumphy to use waterjet to start his business was the software. “The programming software is so easy to learn if you have general machining experience or use of CAD software. We can simply load an image and adjust it as needed, where CAM software on CNC mills and lathes can get a little tricky and time consuming. Plus, it’s simple to draw up a part from scratch,” he said.

The right cutting tool

Any shop machining metal needs a machine tool that can adapt to changing markets, that is easy to use, and that can produce precision parts. For fabrication shops, single purpose machines can be a deal breaker; and for manufacturers, it can be limiting. Shops don’t want to turn away work due to inadequate capabilities, nor do they want to suffer the cost of retooling with every product change.

In the rapidly changing world of machining, you need a tool that can accommodate any metal variation. With abrasive waterjet, you can be assured you have the right cutting tool to easily work whatever metal your company may come across tomorrow or in the future.

 

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Raising Productivity With Plasma Systems

Raising Productivity with Plasma Systems

Here’s how Inoue Kouzai improved its productivity using Hypertherm’s X-Definition plasma system. Article by Lester Lee, Hypertherm.

In today’s fiercely competitive manufacturing environment, the ability to maximize productivity while lowering costs is what sets companies apart from their competitors. Businesses are increasingly looking to the most cost-efficient solutions that also enable them to deliver the best quality products.

For manufacturers in the metalworking industry, investing in cutting technologies that are capable of producing high-quality cut parts at fast speeds, and requires little or no post-production processes, is one of the most crucial management decisions.

Based in Kofu, Yamanashi, Japan, Inoue Kouzai Co. Ltd manufactures steel and non-ferrous parts for a variety of companies, including those from the construction and machinery industries. Since its inception in 1964, Inoue Kouzai has gained a solid reputation due to its emphasis on maintaining customers’ trust and keeping a good record. Inoue Kouzai is also constantly in pursuit of ways to respond to its customers’ diversifying needs, in the interest of retaining its competitive edge.

The search for a better option

To raise its operational efficiency, Inoue Kouzai decided to invest in Hypertherm’s latest X-Definition plasma system, the XPR300. This move allowed the team at Inoue Kouzai to attain optimal productivity, coupled with lower operating costs and better cut quality.

Inoue Kouzai works with several types of metals like mild steel, stainless steel, and aluminum to produce parts for construction and machinery companies. It was important for the company to invest in a cutting system that could perform well on a variety of metals and different types of thickness without compromising on cut quality.

Modern plasma cutting systems have been proven to produce high-quality cuts in the most cost-efficient manner on a myriad of metal types and thicknesses. However, with the recent technological advancements, the X-Definition plasma technology enhances the XPR300’s ability to tackle high-precision applications. When installed on a high-quality cutting machine and equipped with linear ways and elliptical racks, the XPR300 is capable of maintaining ISO 9013 Class 1 and 2 tolerances, and ISO 9013 Range 2 and 3 cut quality. When compared to the XPR300, other alternatives like laser systems required a significantly higher initial investment outlay, while oxy-fuel systems were unable to match the cutting speed and accuracy that the XPR300 offered.

In addition, what Inoue Kouzai found attractive was also Hypertherm’s high level of service standards. The Hypertherm team offered timely response and support to address Inoue Kouzai’s every concern, right from the early stages of decision-making through to after-sales assistance.

Commenting on the company’s reasons for choosing Hypertherm, Shigeyoshi Inoue, CEO of Inoue Kouzai, said, “Hypertherm stood out from everyone else that we were considering mainly because of the rapport we felt with the representatives right from the start, as well as the team’s sincerity and warmth.”

Reaping immediate benefits

Within just months of adopting the Hypertherm innovation, the manufacturer began to reap numerous benefits. Having previously used Hypertherm’s earlier high-definition plasma cutting system—HPR260XD—Inoue Kouzai immediately noticed the improvements the XPR300 has made over the earlier system.

With the XPR300 system, Inoue Kouzai can deliver an edge surface finish that is smoother than that produced with the HPR260XD and extremely consistent edge quality over the full life of a consumable set. The team at Inoue Kouzai now has the ability to fabricate parts with significantly improved edge angularity and cut quality at a lower cost using the XPR300 system, when compared with other plasma or laser cutting systems.

The significantly improved cutting speed and cut quality raised Inoue Kouzai’s ability to fulfil their orders dramatically. In fact, due to increasing demand from their customers over the last couple of years, the manufacturer had been tackling the issue of backorders, and the addition of the XPR300 provided a much-needed boost to their production process.

“With the new XPR300 plasma system, our production team has been able to catch up with the back-orders,” said Yuji Komatsu, factory manager. “The quality of our products is also of utmost importance, and the precise cutting that the XPR300 allows for helps us to ensure we can maintain our excellence while improving our yield.”

Another significant benefit was the improved consumable life, which in turn reduced operating costs for Inoue Kouzai. The highly sophisticated design of the XPR300 includes an Arc response Technology with automatic torch and ramp-down error protection. Sensors in the power supply deliver refined diagnostic codes and enhanced system monitoring information that reduces troubleshooting time and provides proactive system maintenance data for improved system optimization. As a result, the lifespan of consumables is increased by three times, through eliminating the impact of ramp down errors.

“We’ve been using Hypertherm’s industrial cutting solutions for some time now and it has worked well for us, providing us with exactly what we needed to satisfy our customers,” said Inoue. “Our investment in the XPR300 has given us consistent and quality results at a production rate that we’re tremendously pleased with.”

A positive experience

Today, the Hypertherm XPR300 has become such an integral part of Inoue Kouzai’s production process that the team uses it every day of the week.

Inoue concluded, “We’ll continue to leverage on Hypertherm’s XPR300 system as it has worked well for us. In addition, we’ll definitely recommend the X-Definition plasma cutting systems to others looking for a cutting solution that provides improved cut quality, cut speed, and system run time.”

 

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Nissan Metal Forming Technology Can Help Keep Classic Cars On The Road

Nissan Metal Forming Technology Can Help Keep Classic Cars on the Road

For nearly as long as there have been cars, people have been collecting and customizing them. Until recently, however, if classic-car aficionados wanted to replace a damaged hood or fender on an out-of-production vehicle, they had to hire a craftsman to make a replacement or trudge through junkyards. Now, thanks to a new technology called dual-sided dieless forming, Nissan plans to offer original specification pieces at mass-production prices.

Automakers traditionally form body parts by pressing sheet metal against specially created dies. Designing and building multiple dies for each part is expensive and only pays off after stamping a large volume of parts. This basic process has remained largely unchanged since the early days of mass automaking. It remains a stumbling block that prevents low-volume production of inexpensive parts.

Nissan's Plants

Nissan’s new dual-sided dieless forming technology presents a compelling alternative to the investment-intensive industry norm. It does away with dies and stamping machines altogether, removing one of the most costly and time-consuming steps in auto body manufacturing.

Two Robots are Better Than One

The process involves two robots working on opposite sides of a flat sheet of metal. By syncing their movements precisely and using diamond-tipped tools developed by Nissan, the robots can shape the metal to a high degree of accuracy and detail. Working in tandem, two robots can produce intricate concave and convex shapes that could not be created if one robot were working from a single side of the sheet.

“About five years ago, we started thinking about ways of forming sheet metal without relying on dies,” said Keigo Oyamada, an assistant manager in Nissan’s vehicle manufacturing element engineering department, who oversaw the project. “Our goal was to solve the cost issues related to creating dies for small-volume production. We want to put this technology to use to create spare parts for old models whose dies have already been thrown out, or potentially even to let people order custom parts from Nissan.”

New Metal Forming Technology Can Help Keep Classic Cars on the Road-2

Performing a 3D scan of an existing part creates data that can be used to “teach” the robots to build the scanned part—although some human guidance is still required. This approach will allow Nissan to produce parts that haven’t been made in decades, simply by scanning existing examples of those parts.

Performing a 3D scan of an existing part creates data that can be used to “teach” the robots to build the scanned part — although some human guidance is still required.

Custom Parts–In Just One Week

Dual-sided dieless forming can be used to create custom body parts in less than a week, instead of waiting as long as a year for dies to be designed and manufactured. The process is also inherently adaptable, and can be used to produce small and large parts alike, as well as car parts other than body panels.

For now, Nissan plans to use dual-sided dieless forming to produce replacement parts for cars the company no longer sells. Looking further ahead, the company sees potential for creating customized parts for those who are looking to add a little uniqueness to their future rides.

 

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Laser Cutting In An 8-metre Format

Laser Cutting In An 8-metre Format

Langen CNC Metalltechnik GmbH & Co. KG has been successfully processing metal for 30 years. Here’s how the company was able to further increase its cutting capacity by 35 percent by phasing out two equipment, while simultaneously reducing energy consumption. Article by Vanessa Salbert.

Franz Langen (right) in conversation with the operator of the ByStar Fiber 8025. The quality of the cutting edges is essential for the further processing of the parts. A high-quality laser cut eliminates the need for costly reworking.

In northern Germany, Langen CNC Metalltechnik GmbH & Co. KG has been successfully processing metal for 30 years. The family-owned company has continuously invested in state-of-the-art laser cutting technology and infrastructure. Recently, their production hall has become home to a ByStar Fiber 8025 with a customized automation solution from Bystronic.

A green light behind a tinted window, the laser cutting head whizzes around in all directions. With precise and agile movements, it cuts contours out of a metal sheet. The ByStar Fiber 8025 has been in operation at Langen CNC Metalltechnik in the German municipality of Hilkenbrook since February.

“We wanted a machine that cuts efficiently and that is capable of processing large formats. We bend metal parts with lengths of up to eight meters and we, thus, also wanted to be able to cut parts of this size,” explained Franz Langen, Managing Director of Langen CNC Metalltechnik.

Since such a large laser cutting system in combination with an automation solution did not yet exist on the market, a lively exchange was initiated with Bystronic in Switzerland. The result is a powerful 10kW cutting system that cuts 8×2.5-metre metal sheets up to a thickness of 30mm like butter.

An operator from Langen CNC Metalltechnik monitors the cutting process on the ByStar Fiber’s two touch screens. Depending on the configuration, the screens show when which parts will be cut and display all the relevant details of the cutting jobs that are in progress.

Technology and on-site service

Another requirement Langen CNC Metalltechnik had for their ByStar Fiber solution was an automatic loading and unloading system that could handle the large-dimension parts cut by the laser cutting system. And that at any time, the huge cutting table should be able to accommodate either one large metal sheet (8×2.5m) or two standard metal sheets (for example, in the 4x2m format).

“With the Bytrans Cross 8025, we have a system that fulfils precisely these requirements,” said Langen. “The sheets are loaded onto the shuttle table in a fast and reliable process. This increases efficiency and ergonomics throughout the cutting process.”

However, not only the laser cutting machine is important, but also the production environment into which it is integrated. “We needed an alternative solution for the unloading of the trucks that deliver the sheet metal. Before we had the ByStar Fiber 8025, we used forklift trucks,” Langen added.

In order to save time and effort in the future, the company invested in a special magnetic handling technology that can lift sheet metal bundles of up to 5.0 metric tons. “We can now unload 25 tons of sheet metal in just 30 to 40 minutes,” he said.

Cutting capacity increased by 35 percent

The integration of the new laser cutting solution took several months. “We formed a working group for this phase,” Langen said. This was important to ensure everyone involved was on board to help achieve the optimal result for both the staff and the company.

The effort and motivation have paid off. The company currently cuts some 200 metric tons of material per week, which corresponds to 40,000 to 50,000 individual parts.

“Thanks to the new fibre laser system from Bystronic, we have been able to increase our capacity by 35 percent, in spite of phasing out two CO2 laser machines, while simultaneously achieving tremendous energy savings,” Langen said.

Langen CNC Metalltechnik has been manufacturing for more than 30 years. For the past 20 years, the company has relied on cutting technology from Bystronic. The company currently has some 220 employees at its 40,000 square meter site and trains apprentices in six different professions. Most of the parts they produce are used in the special machinery, vehicle, and shipbuilding industries.

“We work for approximately 20 large customers, but we are also pleased to accept small jobs,” Langen said. “We never decline an order.”

In general, the company maintains sustainable, long-term business relationships. “We have been supplying to our oldest customer for almost 30 years,” Langen concluded.

 

For other exclusive articles, visit www.equipment-news.com.

 

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Hexagon Launches Specialist Sheet Metal CAD For CAM

Hexagon Launches Specialist Sheet Metal CAD for CAM

Hexagon’s Manufacturing Intelligence Division has launched Designer, a new piece of specialist CAD for CAM software specifically for sheet metal, alongside the latest release of RADAN.

RADAN Designer will form a pivotal part of RADAN’s CAD/CAM functionality in preparing parts for bending, nesting and cutting. From model design to part repair and modification, it is said to be the ultimate solution for taking geometry through to manufacture.

While the module is available on the new RADAN 2020.1 pricelist, existing RADAN 3D users have the option of a free upgrade. Product Manager Olaf Körner said it contains a material library and several calculation methods to create the correct unfolded shape. “Unfolding parameters such as bend allowances, can be controlled independently of the geometry, leading to more accurate flat blanks, more accurate folding, and ultimately, to a higher quality product.”

A major innovation in RADAN 2020.1 allows for an endless nesting workflow. Körner described nesting in previous releases as being a snapshot. “The operator had a list of parts to produce, and cleaned up the workspace once the nests were finished. They started, finished, cleaned up the workspace and started the next job.”

Now, the new release delivers a more flexible, fluent approach, by enabling parts for additional jobs to continuously go on to the nest, which he says leads to improved machine and sheet utilisation. “It means manufacturers can react to changing priorities. They can simply add more parts without having to clean up the workspace, so the nesting process, and production, keeps going with no interruption,” said Körner.

As common cutting is becoming increasingly popular, RADAN’s support for it has been extended with a new Common Grid Cutting algorithm.

An additional safety check has been added to detect floating scrap in punching programs. The high level of automation, coupled with a target of not leaving anything on the machine, means programs are becoming more complex to ensure that everything’s either destroyed or removed. “If there’s anything wrong in the sequence or applied tooling that might generate floating scrap, RADAN 2020.1 now clearly highlights it.”

Four significant items of new functionality have been added to the Radtube module. Firstly, with information to feed nesters increasingly coming from ERP systems, Radtube can now use CSV files which specify the name of the product, quantity, and other parameters, negating the need to key them in again. Secondly, colour coding of specific parts ensures quick identification. This runs through from the design stage and set-up sheet, so the part can be identified immediately the machine has finished cutting, so the operator doesn’t have to rely on recognising it by shape or size.

The other two items follow on from that and are also linked to identification: improved reporting so that documentation going to the shop floor includes the colour coordination, and introducing a simple line font, instead of a more intricate TrueType font for text marking and imprinting parts.

In Hexagon’s previous release of RADAN, an option was introduced to import 3D files into Radquote, but they had to be single part files. In 2020.1 any multi-body or assembly files can be added. “For example, a complete SolidWorks assembly can simply be dropped into Radquote, which then unfolds all the sheet metal parts and calculates cycle times, to prepare an accurate quote.”

Improved support for bars and tubes includes the ability to set up a complete library of shapes for cutting—not only traditional shapes such as box sections, rectangular and round tubes, I-beams and C-beams, but also custom designs. And as nesting technologies and cycle times are the same for tubes as for 2D, Radquote can provide an accurate cost related to high performance nesting of bars and tubes.

RADAN’s powerful connection with WORKPLAN, Hexagon Production Software’s intelligent project management solution, has been enhanced, both in terms of quoting and nesting. WORKPLAN utilises Radquote to build prices with material costs and production times. It also offers a simple and efficient stock management solution for sheet metal nests, including stock reception/withdrawal, inventory, scrap management and part traceability. Interfaced with RADAN’s CAM programming, data reporting in WORKPLAN and deduction of sheets used, is all readily visible.

Finally, Radbend has been stronger in dealing with programming press brakes for multiple machines, by automating some of the steps. Where tooling is compatible, the time taken to switch a program from one machine to another has been reduced to around 30 per cent of what it used to be. Other improvements include improved workflows. “For example, if there’s a potential collision, Radbend not only notifies the user, but also remembers the action taken when calculating for collisions on an alternative press brake. It’s all about getting to the end result with shorter steps.”

In conclusion, Hexagon’s Körner said RADAN’s roadmap continues to bring all aspects of the software closer together. “For example, 2D nesting and tube nesting have very similar properties; Radquote is becoming as popular in quoting for tube contracts as for sheet metal; and the endless nesting workflow can be used just as effectively for Radtube as flat blanks. It reduces the time required to prepare a quote to around a fifth of what it used to be.”

 

Check these articles out:

Hexagon Touch Probe Transforms Thickness Measurement on Machine Tools

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Hexagon Expands AICON SmartScan Range

Hexagon Releases Complete Solution For Laser Scanning On The Machine Tool

Hexagon Puts Spotlight on Machine Tool Innovation At EMO 2019

Hexagon Launches PC-DMIS 2019 R2

 

 

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BrightLine Weld – A Revolution In Laser Welding

BrightLine Weld – A Revolution In Laser Welding

BrightLine Weld enables low spatter laser welding at feed rates, only achievable today with CO2 lasers. Partial penetration welds for powertrain applications or full penetration welds for pipes and tubes applications – BrightLine Weld has the potential to revolutionise laser welding. Article by TRUMPF.

The technology allows for vastly improved productivity and energy efficiency. High quality weld seams result in high mechanical strengths of components produced. Minimised spatter behaviour reduces contamination of workpieces, clamping devices and optics, as well. That results in reduced machine downtime, less rework of parts, long cover slide lifetime and hence significantly reduced costs.

Introduction And Motivation

Reduction of cycle time and improved productivity play an ever increasing role in current industrial manufacturing. Especially within the automotive industry, where the total length of laser welded seams can add up to 60 metres per car, it is important to minimise processing time by means of high welding speeds. Perfect basis are fibre guided solid state lasers, eg, disk lasers with high beam quality at laser powers in the multi-kW range. Yet, the use of modern solid state lasers comes not for free; obstacles need to be overcome, ie, heavy spatters and contamination of workpieces and clamping devices.

Laser Welding

Compared to conventional welding, laser welding allows for heat conduction welding and deep penetration welding, as well. Thin and deep weld seams can be produced contact free and at high feed rates. A small heat affected zone (HAZ) minimises thermal distortion of parts. Welding depth can be as 10 times larger than the welding width and can reach up to 25 mm.

Yet, feed rates are limited for laser welding. One important factor is spatter behaviour and resulting mass loss of the weld seam. In general, both of these aspects increase with feed rate and laser power used. Solid state laser welding of mild steel typically results in increased mass loss starting from a feed rate of 5 m/min.

Limitations Of Welding With Solid State Lasers

Increased spatter behaviour at higher feed rates:

  • Risk of mass loss at high feed rates leads to side kerfs at the seam front side which results in low mechanical strength and quality of the weld seam.
  • Clamping devices are being contaminated and need to be cleaned. That leads to unproductive machine down-times.
  • Cover slide glasses need to be re-placed often which results in increased costs.

So far, acceptable spatter behaviour could only be achieved at feed rates of up to 5 m/min hence resulting in low productivity.

That is a contradiction to the current demand for reduced cycle time within industrial production facilities. With the new welding technology BrightLine Weld, TRUMPF offers for the first time a solution meeting these requirements.

BrightLine Weld: Low Spatter Welding

BrightLine Weld is a new technology which allows for an almost spatter free welding process during deep penetration welding, even at high feed rates.

Figure 1: Welding depth depending on welding speed. The state of the art is compared with the BrightLine Weld technology.

Slim and deep weld seams produced with BrightLine Weld are of high quality. The low spatter formation results in the process regime extending to significantly higher feed rates. Figure 3 illustrates the welding depth depending on the feed rate at a laser power of 5 kW in mild steel both for the state of the art laser welding and for BrightLine Weld. The colour of the data points in the diagram is an indicator of the quality of the weld seam achieved:

  • Green: weld seam of high quality, which meets current requirements.
  • Yellow: weld seam of medium quality, which does not meet all requirements, but is acceptable for various applications.
  • Red: weld seam of poor quality, which is not acceptable anymore.
  • Violet: from this welding speed humping occurs. The resulting weld seam quality is insufficient.

The data points of the BrightLine Weld curve are green up to a speed of 20 m/min. Up to this range, the weld seam is of high quality. In the state of the art, the data points are yellow at a welding speed of 5 m/min. For even higher welding speeds, they are red or violet. Thus the quality of the weld seam at 5 m/min is only medium and poor or insufficient at higher speeds. This means that with BrightLine Weld, the maximum feed rate in mild steel could be increased by approximately +300 percent up to 20 m/min at a comparable welding depth. In stainless steel, the tests showed an increase in the maximum feed rate by +100 percent to 10 m/min.

Figure 2: Mass loss of the weld seam depending on welding speed for conventional laser welding with solid-state lasers and BrightLine Weld.

Figure 4 shows the mass loss of the partial penetration welds in stainless steel produced with BrightLine Weld in detail. To classify the results, the mass loss measured for conventional laser welding with solid-state lasers is also shown. Red data points again indicate an insufficient weld quality of the test welds. The conventional laser welding process shows an increased mass loss from a feed rate of 5 m/min. The mass loss of the weld seams produced with BrightLine Weld, on the other hand, is up to a feed rate of 20 m/min in a range which can be described as almost spatter free (< 0.4 mg/mm). At the same time, all weld seams made with BrightLine Weld show a high quality. Moreover, the seams have no humping up to a feed rate of at least 20 m/min.

Advantages Of Laser Welding With BrightLine Weld

The use of BrightLine Weld results in the following main advantages for the user:

  • Significantly higher feed rates at a constant seam quality increase productivity. In mild steel the maximum feed rate can be increased without difficulties by +300 percent and in stainless steel by +100 percent.
  • Minimal spatter formation and less contamination reduce cost of ownership. This results in a lower machine downtime, less rework of parts and lower consumption of cover slide glasses at the same time.
  • A lower laser power is required for the same welding depth. The high efficiency allows up to 50 percent energy saving at the same welding depth and at the same quality.
  • BrightLine Weld produces high quality weld seams. In favourable cases, weld seams do neither show undercuts nor end craters. Due to the reduced energy input the part deformation is very low.

How does BrightLine Weld work on real parts? This question is answered in the next section using a powertrain part as application example.

BrightLine Weld In Powertrain

A typical powertrain application is the welding of gear wheels. Depending on type, gear wheels are, eg, welded with a feed rate of 5 m/min and a laser power of 3.4 kW. Spatters which are generated during welding have to be exhausted.

For this application, the BrightLine Weld technology provides a significant improvement. Thereby BrightLine Weld can be used flexibly: either for optimising energy efficiency or for optimising machine productivity. If BrightLine Weld is used to optimise energy efficiency, the identical part can be welded at the same feed rate with a 40 percent lower laser power of 2 kW. With BrightLine Weld slightly slimmer weld seams are produced, which is why less laser power is needed to achieve the same welding depth. At the same time, the spatter formation is reduced, so even no exhaustion is required, hence reducing costs.

For those, who are more focused on improving productivity, they can also increase the feed rate at a higher laser power than in the state of art.

With BrightLine Weld the feed rate could be increased, eg, by up to 220 percent from 5 m/min to 16 m/min while still keeping the mass loss minimal. The result is a high quality weld seam at the welding depth desired.

Outlook

In the future, BrightLine Weld should not only be used in powertrain, but also in other industries such as tubes and profiles.

Tubes and profiles are typically bent and welded from very long sheets (so-called continuous process). In contrast to powertrain applications, these welds are full penetration welds. Commonly, very high feed rates of, eg., 30 m/min are used, which cannot be achieved with solid-state lasers today.

These requirements increase the complexity but promising approaches could already be found. With BrightLine Weld, it is possible to produce full penetration weld seams at high feed rates, which meet the requirements.

Summary

The new technology BrightLine Weld has the potential to revolutionize laser welding with solid state lasers. BrightLine Weld allows for constantly high weld seam quality – independent of the welding speed. The user has the choice between optimising, ie, minimising energy consumption or optimising, ie, maximising productivity of his machine. In addition, the feed rate with BrightLine Weld is no longer a parameter which must be optimised. This makes parameter optimisation easier and accelerates process development.

 

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