A breakthrough in the manufacture of off-set hinges out of sheet metal material follows the development by Wilson Tool International of Swindon that requires only a single tool instead of three on a CNC punch press. In addition, the Wilson Tool design of hinge can be produced with plastic coated material, enables a full 270 deg of hinge movement against traditional hinge movements of 90 deg, will slash tool setting times to produce a hinge by at least 70 per cent and cut production time to a single hit process. The Wilson tool offset hinge tool is able to operate at higher speeds because it only has to travel half the distance of a conventional tooling method when bending the material.

It can produce hinges in up to 3 mm thick material with a 6 mm diameter hinge pin size and in single-hit lengths of 65 mm.

For piano style hinges, successive multiple hits can be repeated using the same tool down the length of the material.

Both the Wilson hinge tool and traditional hinge production require an initial blanking tool to produce the castleation shape.

However, normal hinge production then requires two successive hits to form the material to a 90o bend.

A second tool then creates a half-offset and wipes up the material ready for the third tool to complete the roll-over knuckle form that captivates the hinge pin.

With the Wilson method, after castleation, the single hit tool immediately forms up three knuckles and forms down two knuckles and completes the stroke with a half-roll to finalise the hinge form.

With this method, programming and setting of the tools is much faster and trial and error problems eliminated when setting conventional hinge tools to obtain the right height for the roll-over.

Also, the Wilson Tool design overcomes jamming caused by plastic coatings in the hammer of a conventional tool and eliminates any snagging of coatings in the final curled knuckle form.

http://www.manufacturingtalk.com/news/wil/wil138.html

CNC sheet metal investment raises capabilities A sheet metal subcontractor, specialising in lower-volume, higher-specification work, has invested in a CNC laser cutting system, two press brakes and 3D offline programming software.Brian Palmer, managing director of Tharsus Engineering, has a clear vision of where the company’s future lies, and has just invested in LVD technology to give him the capacity to achieve it. ‘What we want to do is move up the knowledge ladder,’ he says.

‘We have actively tried to specialise in lower-volume, higher-specification work, because if you only quote on volume jobs you risk losing them abroad.

A good job for us is one where we can apply a bit of thought and make money by doing it intelligently.

There are still jobs where we are quoting against drawing, but more and more we are doing the design, making the prototypes and taking it into production.’ The new LVD equipment supplied to Tharsus includes a CNC laser cutting system, two press brakes and CADMAN B 3D offline programming software.

The whole package has been selected to complement existing capabilities, including Radan offline programming software, so that the company has the best possible range of equipment to do the type of work that it wants to target.

According to Palmer, the fundamental reason for buying the laser was that the company’s two punch presses were at saturation point and he needed additional capacity.

‘The laser opens new markets to us and gives us new capability, but it is our job to make sure that we put profitable work on it.

There is a temptation to go and fill up its capacity, but we need to be intelligent and put the work on it that is going to give us the margins.

We are unlikely to have a competitive advantage over a specialist laser shop, for example.

One of the skills we are going to have to develop is routeing jobs intelligently.

There are lot of advantages to having a laser, and it was the one bit of capability that the business didn’t have.

So we knew we wanted a laser and what clinched it for LVD was the Axel’s cost-to-performance ratio.’ The two new press brakes at Tharsus have also been chosen to fill in the gaps in existing capability.

The company already has a press brake with a pressure referencing bend compensation system, but LVD’s Easy Form Laser system offers a number of advantages on certain types of part.

‘The pressure referencing system needs to be operating at 10% of maximum tonnage, but on many of the smaller and thinner parts that Tharsus forms, the bending force may be measured in hundreds of kilos rather than tonnes,’ says Palmer.

‘As with the Axel, the Easy Form Laser press brake complements our existing capacity and offers us advantages in certain areas.

If we are intelligent in the way we use the machines we’ve now got all the bases covered.’ Palmer says: ‘We need this type of system because we are programming offline using the CADMAN B 3D and Radan software and we want to deskill the forming.

Offline programming means that instead of the machines standing idle while someone is doing the programming you can send the program down the wire to the machine.

The operator does not have to know how to program or work out how to produce a complex part, and the Easy Form Laser means that angle correction, which is one of the more skilled elements of press braking, is essentially automated too.’ The final piece in the ‘jigsaw’ is LVD’s recently launched PPRM.

This is a fast, compact machine that takes advantage of reluctance motor technology first developed for the textile industry to achieve far higher bending speeds than conventional hydraulic machines.

It can deliver working speeds of up to 25mm/s and is ideal for bending small- to medium-sized high-precision parts.

Palmer says that before Tharsus had the PPRM the bigger machines were often only bending at a fraction of their capacity - using only a small part of the bed length and tonnage available.

‘A lot of the time we were using 100 tonf (1000kN) , 3m bed length machines to form parts that only required hundreds of kilos of bend force, which meant they were not operating anywhere near as quickly as they could have been.

The PPRM frees up the bigger machines to do what they do best, and it is a faster, more intelligent use of capability.

The PPRM is a light machine - you can move it round with a forklift, it has a very small footprint and the tooling is compatible with our other machines.

It is the highest specification machine of its size on the market.’ * About LVD Strippit - The LVD Strippit Group designs, manufactures and distributes a comprehensive range of sheet metal/plate working equipment, including laser cutting systems, turret 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.

The Group’s UK subsidiary, LVD, has its headquarters, showroom and service centre in Banbury, Oxfordshire.

http://www.manufacturingtalk.com/news/lvd/lvd152.html

EXPERT CAD/CAM is the only fully functional sheet metal CAD/CAM system that offers its users seamless integration between automated CNC programming and a full suite of production control modules all within the one user interface.Available from Shera Bonnet and Associates, Version 25 makes use of Microsoft’s SQL Server database technologies to combine all of your production control information with your Nesting, Materials, and sub operation requirements, all in a multi-user environment.

Solid Works, Solid Edge & Inventor 3D Models

Lantek Expert Punch and Cut allows transparent data transfer between these three popular 3D Modelling systems and your CNC Programming environment. Forget about DXf file transfers, just add one custom button in your 3D modelling system and our Intelligent Expert system will do the rest.

If you know Mazatrol then you will know Camlink

Griffo Bros Inc has released its latest benefit for Mazak/Mazatrol users. You can now work directly in Solid Works and translate your modeling features directly into Mazatrol.

Camlink 2006 will support Fusion and 640MT controllers ensuring higher levels of productivity with the world’s best in Mazatrol emulation software.

Camlink will also work directly with your existing CAD system, with its extensive range of modules for communications, printing, editing, translation of old programs to new controls, graphics check, and toolpath.

Automate your shop floor communications with PC-DNC PLUS. Take advantage of advanced features included in many new modules. Works for just one CNC or up to 128 CNCs from one PC.

Shera Bonnet and Associates will be on stand xxx at Austech 2006 from May 30 to June 2 being held in Darling Harbour at the Sydney Exhibition Centre.

http://www.ferret.com.au/articles/20/0c03ea20.asp

Matt Fowles, sales and marketing manager of LVD commented: ‘Continuing on from our strong performance in the back end of 2005 and the start of 2006, MACH 2006 was important to us to further ’spring board’ LVD’s profile in the market place. The MACH show enabled us to demonstrate a selection of LVD’s ‘high end’ machine tool and software solutions for sheet metalworking, some of which had never been exhibited in the UK before. Existing and particularly new customers commented on how impressed they were with how far LVD’s sheet metalworking technology has advanced.

Many clients commenting on how LVD’s integrated, intelligent and configurable approach to sheet metalworking can provide them with a flexible, productive and an integrated solution to their production needs.’ The show provided some immediate success for LVD with several orders being secured.

These included Garrick Engineering of Southport who purchased the High Speed Axel 3015 5kW Linear CNC laser cutting machine being shown at MACH, Magnetic Shields, from Kent, who purchased one of LVD’s cost effective - Orion 3015 2.5kW CNC laser cutting machines and De-Met from the West Midlands which purchased a new LVD Siena CNC Punch Press.

LVD also enjoyed great success with its PPEB Easy Form Laser CNC Pressbrakes with several customers placing orders at the show after being shown LVD’s Easy Form Laser System (real time in process angle monitoring and correction) in action.

Orders for Easy Form Laser Pressbrakes included B and S Design from Chester, Tiernan Automation from Rugby and Nichol McKay from Scotland.

These companies have bought into LVD’s ‘Art to Part and ‘First Part - Right Part’ technology combining LVD’s CADMAN offline software and LVD’s PPEB Pressbrake with Easy Form Laser technology in one complete bending solution.

Fowles further commented: ‘Whilst it was great to achieve immediate success at the show the main thing that has impressed us is the high quality of forward interest in machines and solutions.

We are looking forward to discussing and demonstrating to new and existing clients how we can provide them with an integrated, intelligent, configurable and affordable solution to their manufacturing challenges.’ * About LVD - the LVD group 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, turret 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.

The Group’s UK subsidiary, LVD, has its headquarters, showroom and service centre in Banbury, Oxfordshire.

http://www.manufacturingtalk.com/news/lvd/lvd157.html

Tuscaloosa, AL, February 5, 2007: Radan 07, the latest version of Radan’s industry leading CAD/CAM software for sheet metal applications is now shipping to customers in the USA.

The key focus for the latest release is Material Utilization, helping our users combat the ever rising cost of raw materials. “True Shape” nesting capabilities allow the user to nest components around clamps, provide angular orientation of parts within the nest and accurately compensate for individual tool shapes. Also in Radan 07 is an improved remnant handling method – with automatic recording of material for re-use in our “Remnant Nesting/Remnant Tracking” tool.

Also featured is the latest release of Radbend CNC for offline programming of press brake machines with full 3D model simulation of the bending process. Combining high productivity with ease of use, the software includes features such as automatic bend sequence calculation, automatic tool selection and automatic finger stop placement, as well as powerful collision detection of components with the machine and its tooling. By programming and verifying bending operations offline, Radbend CNC frees up valuable machine time and reduces manufacturing costs. With the 07 release, the software supports an even wider range of machine tools, including Amada, Beyeler, Accurpress, LVD, Finnpower, Pullmax/Ursviken and Trumpf.

http://www10.mcadcafe.com/nbc/articles/view_article.php?section=CorpNews&articleid=349858

With humble beginnings in 1979, Metaltex has progressed into one of Victoria’s leading boutique sheetmetal manufacturers.Founded by John Pieterson in order to become his own boss, Metaltex owned no machinery; everything was made by hand. Metaltex set up shop in Union Rd and steadily increased in size and performance and added to its repertoire of skills and product lines. Metaltex past exploits hand included a series of custom electric cars for various applications, some pretty unique BBQs and it manufactured and fit the entire bar and galley arrangement for the bar Cookie in Melbourne.

Metaltex’s current workload includes customers from the Pharmaceutical industry, Truck and Trailer manufacturers, Council projects, Diesel tanks and a plethora of general sheetmetal. Some of these customers have been with Metaltex since its inception. Metaltex is now being run by John’s two sons. Both are A Grade sheetmetal workers and display their skills through their hands on approach to the business. It is not unusual to see them in the factory leading by example.

A large part of the success of Metaltex is its unfaltering dedication to quality. Strict quality controls at all parts of the process ensure that their customers receive what they want. Metaltex’s recent growth has been largely attributed to this drive for quality.

The staff level at Metaltex has seen a recent surge due to a massive workload increase. Several of its large customers came to Metaltex after prior suppliers were not delivering the required quality and were not meeting deadlines. The workforce actually tripled in the last 18 months, a true reflection of the good work performed.

In August of 2005, Metaltex purchased its first Durma machine. A 200mm x 4mm variable angle notcher. 6 months later the purchase of three more Durma machines, a 4 metre, 160 tonne NC Press Brake. 3 metre, 80 tonne CNC press brake and a 4 metre, 6mm Swing Beam guillotine further strengthened Metaltex’s position.

Now 2 years on, almost to the day since the notcher was installed, Metaltex has added yet another Durma Press Brake to its ranks. A new series AD-S Synchro CNC press brake with X/R backgauge and LazerSafe guarding. This machine is new from Durma and features the Cybelec ModEva10s graphical interface.

A new turret punch is also currently being installed, allowing Metaltex to prepare its own blanks for folding. In-house blank processing allows Metaltex to control both the quality and lead time of parts.

These two new purchases come hot on the heels of Metaltex’s major relocation. Moving from its original Union Road location into the new estate on Micro Circuit in Dandenong. In the constant push for further capabilities, Metaltex has invested in 3D design software allowing it to provide not only the end product, but the detail design of the product also. The idea need only be sketched and Metaltex can produce it. This allows Metaltex to develop a more personal relationship with its customers leading to more a more rewarding experience for both parties. Not content to rest, Metaltex is aiming for full ISO9001 accreditation but the end of this year.

This constant striving for improvement is reaping tangible rewards for Metaltex through Quality, reliability and a strict code of ethics.

http://www.ferret.com.au/articles/z1/view.asp?id=34081

Real consumption of flat steel products, which has failed to recover, remains lacklustre and now scrap costs have started to slide, with two consecutive monthly drops

The recent upward price trend in the USA has not been sustained. We have noted modest price reductions for most strip mill products. A combination of factors is responsible for the deterioration. Although service centre inventories are declining, they are still above the desired level and the destocking phase persists.

Real consumption, which has failed to recover, remains lacklustre and now scrap costs have started to slide, with two consecutive monthly drops.

However, import competition continues to be low, due to the weak dollar and good demand elsewhere in the world.

These same conditions are encouraging US mills to start looking at export opportunities.
Imports are currently not a factor in the Canadian market, with lead times out to September.
In the Ontario region, producers are reporting slower demand from the auto and manufacturing sectors.

Service centre inventories are comfortable at 2 to 2.5 months supply but we have reports of falling business levels.
Order books at the mills have weakened, resulting in some discounting.

The return from the extended early May holidays has heralded a number of positive price developments in the Chinese market.

Export business continues to flourish.

It is difficult to assess how the steel export licencing system together with the export tax levy and the strengthening exchange rate between the Yuan and US dollar will affect overseas transactions in the longer term.

Many of the implications are set out in the MEPS on-line forecasts.
Japanese domestic demand, particularly from the auto and shipbuilding sectors, remains buoyant.

The export climate is also healthy.

However, total domestic inventories of strip mill products held by steelmakers and service centres, at end March, climbed 1.25% - reversing the previous month’s fall of 2.4%.

They have now moved back above the 4 million tonne level considered appropriate.
Quayside stocks lost 9.4% in the same time-frame.

South Korean sales have shown some positive movements, mainly for seasonal reasons.
In Taiwan, domestic market sentiment is quite robust at present.

Even so, the future outlook is unclear because of increasing global slab and scrap prices, together with the question mark over Chinese exports, which at the moment are adversely affecting Taiwanese sales to overseas customers.

The Polish economic situation continues to progress well, creating excellent sales opportunities for the steel mills.

In the Czech and Slovak markets prices are slightly up this month amidst good demand.
Inventories are at normal levels and supply is adequate.

No serious discussions regarding third quarter prices have taken place so far.
There is virtually no import pressure.

West European flat product prices are generally stable, whilst producers are mulling some further rises for the July/September period.

However, buyers are anticipating little change in the second half of the year.
Third country price offers continue to stay at higher levels than those quoted at the start of 2007.

http://www.manufacturingtalk.com/news/msi/msi321.html

Three seats of Radan’s powerful sheet metal CAD/CAM software and has subsequently seen lead times at heating and cooling equipment manufacturer shrink from typically six to three weeksInnovative product development is contributing to the growth of heating and cooling equipment manufacturer Dunham-Bush, in conjunction with ongoing investment in the latest technology to design innovative solutions that exceed customer’s expectations. In 2005, the company installed three seats of Radan’s powerful sheet metal CAD/CAM software and has subsequently seen lead times shrink from typically six to three weeks.

Dunham-Bush is the result of the merger in the early 1950s of three manufacturing companies founded in the late 1900s and the early part of the 20th century.

The new company introduced water and glycol chillers for commercial and industrial applications and in the 1960s, a revolutionary technology in the form of the rotary screw compressor.

Providing custom-engineered solutions is fundamental to the success of the company and as such, a CAD/CAM system that could handle its extensive sheet metal work was an absolute necessity.

The machine set-up at Dunham-Bush includes three Amada punch presses: a 200kN Vipros 255, a 200kN EM 2510 NT and a 300kN Pega 367 working two or sometimes three shifts.

‘Sheet metal forming is central to our manufacturing operation,’ explained technical director David Shuttleworth.

‘Metal sheets up to 2mm thick are punched for casework, etc, for our range of heating and cooling products.

We need to utilise the best technology and equipment to ensure optimum efficiency and provide customers with quality products.’ He said: ‘The system we had been using previously did what we wanted in many ways it was perfectly capable of creating the forms we required but it did not provide the process specific tools to allow us to then take these parts into manufacture.

With the volumes of work we handle involving punching, profiling and folding of sheet metal we needed tools with a high degree of functionality that would support the whole process from design through production preparation to manufacture.’ Shuttleworth said: ‘We had been monitoring solid modelling packages for some time before installing Inventor and Radan around two years ago and with experience in using AutoCAD previously, it was a fairly easy transition.

We were able to easily transfer 3D models, including material types and profiles, into Radan via DTM transfer.’ The Inventor and Radan system was also attractive to Dunham-Bush because it offered a much more comprehensive support package a vital requirement for the company, especially when making changes to a new product.

‘The guys at Radan are always prepared to help us by coming up with imaginative solutions to problems we encounter from time to time,’ commented production engineer Glenn Syder.

‘The process of designing in CAD through to CNC manufacturing using Radan, gives accuracy and repeatability, and eliminates the human error aspect which was always a possibility when we relied heavily on manual transfer of information.’ In driving all changes from the design model, all parts are in one directory that enables the same data to be used each time.

With two-way exchange between drawing and solid model, an updated drawing is generated from the approved design every time changes are made, and the machine program is then based on the latest version.

‘We are able to utilise material more effectively, so there is less wastage and with the price of steel increasing all the time, that is a significant saving,’ says Syder.

‘The system pays for itself on that basis alone.

Radan takes direct control over the process from the shop floor back to the planning department.

We have been able to reduce lead times from six to three weeks from the time an order is placed and don’t require so much line stock that will decrease further as we use all the features of Radan to their full potential.

Our maintenance agreement with Radan ensures we are kept up-to-date with software updates which are relevant to our particular manufacturing processes’.

* About Dunham-Bush - for most of the last century, Dunham-Bush has been providing innovative solutions for the heating, air conditioning and refrigeration needs of its customers.

Examples of leading edge technology marketed internationally through well-known brand names include advanced compressors, ultra-quiet packaged chillers, wall mount and ceiling exposed split air conditioners, new-age air handling equipment, ice thermal storage, and architecturally oriented heating equipment.

Dunham-Bush equipment plays a pivotal role in manufacturing comfortable living and working environments in new building construction and in the renovation of existing structures such as schools, hospitals and other institutions, delivering unequalled performance and durability.

For more information visit .

* About Radan - Radan is the most powerful sheet metal CAD/CAM software in the world, helping customers increase their material utilisation and reduce inventory and offers a significant return on investment.

Radan is a principal brand of the Planit group.

Planit is a global supplier of design and manufacturing software for the engineering, woodworking and stone industries.

The company provides its customers with products and services that enable them to improve the productivity of their machine tools, shorten design and manufacturing time, optimise material usage and deliver high quality goods and services to their customers.

Planit’s solutions are best-in-class within their respective markets and are integral to the success of thousands of companies of every size around the globe.

http://www.manufacturingtalk.com/news/rda/rda126.html

ADVANCE Metal Products, CNC sheetmetal subcontract manufacturer, utilises the innovative Finn-Power L+P Combo machine.It is suitable for sophisticated components, with several work stages performed automatically on one machine.
Its versatility is paired with integrated laser cutting in LPE 5. The combination of electrical servo technology and mechanical power transmission offers high punching and forming accuracy.

As consecutive forming strokes can be programmed to different stroke positions, intricate bends can be achieved. It can punch, form, tap, mark and laser cut, allowing component manufacturing to be planned for optimum quality and speed of production.

http://www.ferret.com.au/articles/f6/0c034cf6.asp

A longstanding Australian supplier of machinery and automation to the sheetmetal industry believes a generational change is taking place where automation will all but replace manual processes on the production line.

Managing Director of Power Machinery, Mr Ken Christensen, believes various aspects of the industry are pointing towards this while machine sales certainly support this forecast.

“Many aspects of sheetmetal fabrication have changed dramatically in the last 10 to 20 years and these are very much dictating the reshaping of the industry,” said Mr Christensen.

“These include heightened operator skills, better attention to occupational health and safety, strong focus on production line integration, and a natural regeneration of the workforce bringing in completely new attitudes that are effecting change.

“It is all shaping the way we are thinking about how we bend, cut, punch, shear, press and collate our work.”

“As a supplier of both used and new machinery for this industry, we definitely see a new trend where traditionally manual operators now see the economic viability and sensibilities in automating their plants as much as practicable,” said Mr Christensen.

Skills based issues have created the new dominant factor changing the industry landscape. Young operators come into the workforce, representing the next generation, are more likely to be at ease with modern CNC machinery whereas more longstanding staff may prefer traditional methods.

In contrast to the new generation preferring the modern CNC equipment the older manually operated machines literally have to be removed from the building before the longstanding operators will make the leap.

As power machinery supplies both used and new machinery across the fabrication spectrum, the company often fields many points of discussion from confused plant managers but finds that open dialogue always leads to a strategic choice by its customer.

“Occupational health and safety is also a very big issue nowadays - and a potentially expensive issue if not approach correctly,” said Mr Christensen.

“In the manufacturing process, it has been shown that one of the most common injuries is back strains so many plant owners are now opting for a significant level of automation or at least ergonomic assistance in the material handling process.”

“Particularly the European machine tool manufacturers are working hard to provide the right solutions; for example, it is common that press brakes will be fitted with a swing devices to support the sheet. This is already prevalent in Europe and with the high cost of rehabilitation is inevitable in most Western countries.”

“A further extension of this is complete robotic bending cells. This essentially takes the laborious side of the bending process out all together.”

“Change is taking place a rapid pace, but the industry is well served knowing that these changes are happening from all angles and complete shopfloor integration seems a very likely outcome and this should benefit fabrication shops of all sizes.”

“Much of it is being driven and integrated by software, and with young minds coming into this workforce with fresh ideas there is likely to be a natural upskilling of the fabrication plant.”

“It is likely to make the industry more dynamic and Australia more globally competitive and far more integrated than anyone would have thought possible less than 20 years ago.”

http://www.ferret.com.au/articles/z1/view.asp?id=53885