Running a variety of CNC punch presses, a punch/laser press and adding on a new machine has not posed any problems or interruptions using just one CAM system

Wilhelm Bott produces factory and service car racking systems and has used CNC punch presses since the mid 1990’s. Based in Gaildorf, near Stuttgart, Germany, Bott claims to have the most modern production lines in Europe. It operates a Trumpf 6000L CNC punch/laser combination (2002) and a 5000R CNC punch press (2006).

Bott’s material handling system links with both machines.

Franz Maltan, Bott’s production manager, said: ‘We had a situation in the 1990s where we had two cam systems driving several different machines.

When we found out that development on one system had stopped for some time, in 2002 we decided to standardise on the other, which was JETCAM.’ After ordering a new Trumpf CNC punch press in 2006 and a SheetMaster sheet metal handling system for the 6000L, Bott decided to streamline its production processes.

For the two SheetMasters a materials handling system was introduced based on a 50m Stopa stock system.

Trumpf’s TrumaGrip removes scrap skeletons from both machines.
The scrap skeletons are then reduced by the Scrap Shear system.

A ’stand-alone’ Finn-Power CNC punch press processes smaller, urgent jobs.

* Programming system - ‘When looking for programming solutions we looked at alternative products but we found nothing that was even near to the user-friendliness of JETCAM.

At the beginning of the evaluation process we had concerns that the software would not be able to drive all of the advanced features of the Trumpf machines, but JETCAM has always generated 100% reliable code.’ It was after Bott had purchased the Trumpf 5000R CNC punch press that the company realised that they had over 20,000 parts to run on it.

All cutting technologies were stored on a single geometry file within JETCAM so all parts could be automatically retooled within seconds for the 5000R.

In many cases jobs that were nested for the previous punching machines or for ‘punch-only’ jobs programmed for the combination punch/laser press were immediately available for reuse without renesting.

Revision control in the software ensured that changes on components were automatically applied to all relevant nests for all machines.

Bott had a further requirement that information of components unloaded by the SheetMasters had to be passed to Bott’s bending centre.

JETCAM’s postprocessed NC code was modified to provide part positions.

The data was passed from the punch press or laser to the stock management system, which in turn instructed the bending cell of the parts location.

Programmer Eduard Reisenbuechler added: ‘Over the years we have programmed our machine tools very successfully with JETCAM, but the control of the new machines’ functions along with regular update of software has been a huge step forward for us.

Full training and modifications to the new post processors to match our requirements were made in only two days.

Since that day our entire facility has run with zero interruptions’.

Reisenbuechler concluded: ‘With updates that we have seen under maintenance to both the core software and the postprocessors, the control of many feature has been enhanced.

Additional functions such as SheetMaster and Grip work very well and are easy to adopt and apply to existing nests.

We have an extended number of options for programming the unloading chutes.

With special tools such as wheels, multitool and multishear we only have to enter the relevant parameters once - the rest is done by the software.

Where we were aiming to achieve complex levels of automation and needed assistance blechwelt were able to connect to us remotely, and we were always able to solve it together.’ Benefits of the JETCAM system have been summarised as follows.

* Running all functions of the new Trumpf CNC punch press and existing punch and punch/laser presses, as well as the existing Finn-Power CNC punch press.

* 100% accurate NC code output, which was customised to allow complete flexible manufacturing system integration.

* 20,000+ parts were immediately available on new CNC punch press due to tooling being stored in geometry file.

* Revision control providing traceability of component versions within nests, which are automatically updated.

* Only two days required for training and customisation.

* Maintenance delivering continual software benefits.

* Excellent local dealer support.

Sheet metal working production system operated now includes as follows.

* JETCAM Expert Premium with auto-nesting interface and Rectangular Automatic nesting module.

* Trumpf Trumatic 6000L CNC punch/laser press with SheetMaster handling system.

* Trumpf Trumatic 5000R CNC punch press with SheetMaster.

* Finn-Power F5-25FBV CNC punch press.

* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.

In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma-arc, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.

http://www.manufacturingtalk.com/news/jea/jea167.html

Robust, thick turret tooling style CNC punch presses, 200 and 300kN, offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry

LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.

Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.

A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.

Bridge frame construction provides accuracy and durability.

LVD’s latest punch presses handle workpieces up to 1524 x 2500mm depending on model.

Larger workpieces are handled with clamp repositioning.

Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.

* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona’s high-speed operation while reducing noise and shock.

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

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.

Up to 48-station turret capacity - Verona’s large and versatile double-track turret provides flexibility and easy set- up.

Every station accepts shaped punches and dies, reducing set-up time.

A unique mix of turret stations provides exceptional capacity.

Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.

The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.

The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.

Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.

* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.

This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.

The punch press accommodates the latest in tooling technology for high-performance fabricating.

These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.

Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.

Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.

* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.

Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.

* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.

LVD’s automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.

Verona may be integrated with a robotic Pick-Sort material handling system.

The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.

The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.

* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.

http://www.manufacturingtalk.com/news/lvd/lvd164.html

system is designed to produce threaded holes at high speeds and with repeatable quality in all types of sheet metal - including SS, mild steel and aluminium -in thick turret punch presses
Related stories

Tool systems fit punching requirements
Danobat Punch Press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements

Punch press tooling firm announces promotions
Manufacturer of tooling equipment and systems for punch presses, Mate Precision Tooling, has announced a number of international sales management promotions

Mate Precision Tooling leads the punching industry with an all-new tool system designed to produce threaded holes in all types of sheet metal in thick turret punch presses. Called Mate EasyTap™, his unique tool system extends the punching capabilities of todays CNC punch presses by producing precisely located threaded holes at high speed, automatically and with repeatable quality.

Because Mate EasyTap produces threaded holes on the punch press, there is no need for secondary tapping operations either by hand or with adjacent machines.

The threaded holes are produced in pre-punched holes or in extruded holes located on the sheet.

Mate EasyTap tooling is designed to operate in thick turret presses equipped with auto index stations, programmable ram depth capability, and suitable software.

The thread tapping operation is accomplished automatically through a coordinated rotation of the turret press auto index station and the ram stroke.

The tooling will produce a full range of threaded hole diameters in most materials including stainless steel, mild steel, and aluminum.
Further reading

CNC punch press tooling catalogue published
Euromac Punch Press users will find the new and expanded 36 page Mate Euromac tooling catalog helpful in planning their fabricating projects

Verify CNC turret punch press precision
Punch press calibration system for aligning and verifying CNC punch press precision is designed to operate on a broad range of press types, including those with eccentric turrets

Mate Precision Tooling has appointed Baeumler
Frank Baeumler Appointed Vice President European Operations And Managing Director Of Mate Germany

Continuous card guide tool does more work
Continuous card guide tool simplifies producing card guides in electronic assemblies and any length card guide now can be fabricated, eliminating multiple tools and secondary operations

Mate EasyTap tooling is fast to setup and install.

It has a design that uses standard taps and Bilz brand collets to produce the threaded holes.

A push button length adjustment feature sets the tap length.

Additional important Mate EasyTap features include: automatic lubrication system that dispenses a pre-set amount of lubrication to the tap point with each tapping cycle; built-in lubrication level sight gauge; pre-pierce hole ‘miss protection’ prevents tool and part damage in the event of the absence of a pre-pierced hole; lower tool assembly with integral ball bearings prevents under-sheet marking; precision machined guides made from hardened tool steel for accurate, long-life operation; supplied with compact table-top setup and storage stand to protect tooling and make setup easy.

According to Frank Baeumler, Vice President Marketing for Mate Precision Tooling, Mate EasyTap is the companys most significant new application tooling design because it adds broad versatility to existing turret press capabilities with only nominal tool investment.

‘Mate EasyTap tooling system gives the product designer a new option for more cost-effective manufacturability,’ Baeumler reported.

‘This tool totally eliminates the need for secondary tapping operations.

Sheets requiring integral threaded holes can have these holes produced on the punch press with all the CNC accuracy of the press.

Since this is a tool, it can be installed into the press when the job requires taps, and then can be removed from the press when the station is needed for other punching requirements.

The resulting taps have extra holding strength when fastening components since the parts are assembled directly to one another.’ Mate EasyTap is an ideal addition to Mates other application specific tooling for producing hinges, bends, interlocking components and custom markings, to name just a few.

All of these features can be fabricated on a single punch press automatically with high speed and repeatable quality when tooled with Mate.

http://articles.onlineb2bmarket.com/category/cnc-punching/

punch press programming software selected as it was easier to learn than other systems and generates 100% reliable code for all a user’s machines

Gazco, based in Exeter, Devon, UK, manufactures gas fires and stoves, and Redfire range cookers with its 130 strong workforce. In 1997 they purchased a Trumpf 180 CNC punch press. Said Jim Stevens, production director: ‘Prior to this point we had no experience of operating a punching machine, let alone programming for it.

I embarked on a benchmark of several systems, which quickly boiled down to two major UK vendors, one of which was JETCAM.

Quite frankly, the other system we evaluated frightened me because of its complexity.’ They selected JETCAM, which was installed in 1998.

Three people were trained, one of which had never used a PC before.

Said JStevens: ‘One of our machine operators had never even touched a PC before, but she was able to produce code reliably within about 90 minutes.

Although the JETCAM engineer was here for the allotted two days, most of it was only in an advisory capacity rather than needing to train us on an overly complex system.’ In 2000 Gazco added a TC500 punch to the shopfloor, with another postprocessor installed into JETCAM.

Installation was fast, with all parts immediately available for cutting on the new machine.

Added Stevens: ‘The engineer was not ‘just’ a software guy - he was also knowledgeable about the machine itself.’ In 2006 Gazco sold the TC180 and TC500, replacing them with a new TC500 with SheetMaster load/unloading, which is running at full capacity, cutting parts from a database of over 4500, plus prototypes.

‘Speed to market is critical, but also one of our biggest advantages - we are able to produce prototypes much quicker in-house than external vendors, much of which is related to our ability to swiftly and reliably convert a CAD file into NC code.

We have never needed to actually ‘know’ anything about the NC code that is generated as it always works.’ Approximately 30% of Gazco’s parts are runs of a single component, so they make use of JETCAM’s Single Component Automatic Processing (SCAP) function.

This allows a CAD file to be automatically nested within given parameters and tolerances, such as rotations allowed, microtagging or unloading etc, and then NC code being generated within seconds.

Said Stevens: ‘As over 90% of our work is for stocked parts, the ability to create a nest in this way, or to quickly add items to an existing nest using bump nesting is extremely important.

This has had a ‘knock-on effect’ of reducing overall stockholding, especially important for slower moving items.’ A change in tooling was considered at the same time as the purchase of the new TC500 and subsequently implemented, with a 76mm slitting tool replacing the 56mm.

Stevens stated: ‘This was a non-issue with JETCAM as all of our parts could very quickly be retooled for the new configuration, and therefore did not impact on the decision.’ Gazco also subscribed to an annual maintenance contract, providing support and software updates.

While Stevens could cite many advantages received in updates he was unable to comment on the quality of support.

‘It’s hard to comment on technical support as I can’t recall ever having to use it.

Changes we’ve seen in the software over the years have only continued to emphasise its ease of use and further reduce machining and programming time.’ Gazco has plans to rapidly grow the business further within the next few years, with JETCAM crucial to this plan.

Stevens concluded: ‘Programming is not a ‘value added’ activity - by using JETCAM we are saving wasted time through automation.’ Benefits achieved are as follows.

* Much easier to learn than other systems benchmarked.

* Generates 100% reliable code for all machines Gazco has programmed for.

* Ability to quickly change a part or its tooling not an issue when considering new tooling configuration.

* Reduced stocks due to ability to quickly nest components as required.

* Users with no PC experience able to design and program parts within 1.1/2h * Around 30% of components are auto-nested using SCAP.

* From CAD file to CNC program without any knowledge of CNC code.

* Machine running at full capacity with minimal programming time.

* Lower ongoing costs.

* No calls made by user to support usage.

http://www.manufacturingtalk.com/news/jea/jea152.html

punch press that is as easy to install, operate and program includes three-dimensional forming and tapping can also produce profiles quickly, easily and economically

The new Trumatic 1000 Rotation from Trumpf has a rare combination of attributes. No other punching machine is as easy to install, operate and program. It is therefore the ideal choice for those new to automated sheet metalworking. However despite being a low-priced, entry-level machine the TC1000 is no low-end performer.

The TC1000 has the same process capability as a larger Trumatic including three-dimensional forming and tapping.

It can also produce ‘extrusions’ (formed profiles - Ed) quickly, easily and economically in one machine set-up.

Although primarily aimed at those with little or no programming experience the TC1000 is also an excellent stand-alone, supplementary production unit for established users.

It has a working range of 2070 x 1280mm without repositioning and can accommodate materials up to 6.4mm thick.

A key feature of this new addition to the Trumatic range is the simplicity of programming.

This is the first machine to include a new Trumpf navigation system that transparently guides beginners through the programming of simple parts and into the use of the ToPs 300 basic software.

The ToPs system allows more complex features to be added.

An NC programme is generated automatically in just three steps even for complex contours.

Having guided the programmer through the process of creating a drawing the software assists in the definition of the sheet layout to minimise material wastage.

The system then recommends the optimum tool path and process sequence.

Machine operation is via touch screen.

Naturally the control system has a modern user interface with a selection menu that is tailored to the operator’s exact needs.

The hydraulic single station punching head featured on the TC1000 allows the use of angled punching tools to optimise punching force.

As all tools can be rotated a full 360 deg fewer tools are needed, set-up costs are reduced and higher processing speeds achieved.

Tools are changed in just 4s and with Multitools exchange time is even quicker; their use allows up to 150 tools to be held in the machine’s linear magazine.

The TC1000 can achieve stroke rates of 600/min for punching and 1300/min for marking.

Ram guidance ensures high dimensional accuracy by ensuring the punch and die are always exactly aligned.

All punching tool options can be used on the TC1000 including Multibend to bend flanges and Multishear for burr-free edging.

Other tools for beading, threading, louvring, embossing and parts marking extend the scope of this new machine.

Small parts are ejected through a fixed chute directly into a container.

Parts up to 180×500mm can be removed with an optional, programmable support table.

By retracting the tables parts up to 450×500mm can be removed automatically.

A special pushout tool prevents thin parts from catching in the scrap skeleton ensuring a high level of process reliability.

http://www.manufacturingtalk.com/news/tru/tru224.html

Precision sheet metal working subcontractor has had installed one of th latest CNC punching centres, which with 2G axis accelerations offers higher productivity

Fife Fabrications in Glenrothes, UK, has commissioned a GBP 700,000 CNC TruPunch 5000 sheet metal punching centre machine in order to compete more effectively against low cost producers overseas. Believed to be the first of its model to be used in the UK, the TruPunch 5000 sheet metal punching centre was ’switched on’ by Councillor Tony Martin, Chair of Environment and Transport at Fife Council and Dr Peter T Hughes, Chief Executive of Scottish Engineering.

Fife Fabrications, in a report to Manufacturingtalk, said that investment iis part of a GBP 2.5 million pound redevelopment plan and the six figure expenditure will give the company a productive and energy efficient punching machine.

Fife Fabrications’ managing director, Archie Smith, told Manufacturingtalk that: ‘Britain’s manufacturing industry has been very hard hit by low cost manufacturing competitors in the Europe/Far East who are able to use their incredibly cheap labour costs to undercut UK manufacturers’.

‘There is only one way to handle this and that is through radically improving our skills, productivity and manufacturing flexibility.

I am incredibly proud of the Fife Fabrications team who share my vision of how we must continually improve.

We believe that the provision of the highest quality and service across our operation will drive our success.

Our continuous improvement systems, key performance indicators, dedication to lean manufacturing and Total Quality Management focuses every employee’s attention on the need to maintain the highest possible standards of excellence’.

He added: ‘This has to be combined with radically improving the productivity of our manufacturing equipment.

Our new punching centre is a perfect example.

It is the most productive machine of its type available, 15% greater than previously available.

Not only does it manufacture products more quickly and to higher quality levels, it also removes extra work steps by including further processes in the machine’.

Continuing, Smith enthused: ‘The speeds are amazing, the axis which moves the tooling over the sheet metal pulls 2G - like a formula 1 car cornering and moves at 100 meters a minute! The machine will reduce the time it takes to manufacture each product and will use less energy.

It will make Fife Fabrications more flexible, more competitive and help us meet our energy reduction targets.

This will secure jobs in Fife Fabrications into the future’.

Chief Executive of Scottish Engineering, Dr Peter T Hughes, said: ‘Fife Fabrications Limited is proving to be an excellent standard bearer for the Scottish Engineering Manufacturing Sector.

The company has shown steady growth over the years and has consistently invested in staff training and the procurement of world-class equipment, a combination which has allowed them to tackle the ever-changing and competitive world in which they operate.

Scottish Engineering congratulates everyone involved with this latest acquisition.’ As councillor Tony Martin, chair of the Environment and Transport Committee at Fife Council switched on the punching centre., he told Manufacturingtalk: ‘Fife Fabrication’s investment is a tremendous boost to manufacturing in Fife and Scotland’.

‘It puts FiFab at the forefront of sheet metal technology.

This investment reflects the company’s forward thinking attitude to developing the business and shows confidence in both FiFab and Fife.

At Fife Council we have enjoyed a very good relationship with FiFab and wish them continued success.’

http://www.manufacturingtalk.com/news/fiw/fiw104.html

GP Precision, a New Jersey-based precision sheet metal fabricator, was founded in 1966 to serve the prototype market of the electronics industry. Their original shop in Morris Plains, New Jersey, was expanded three times before they moved to Hackettstown in 1985. This doubled their shop size and allowed them to expand their capabilities to include production runs. They moved again in October 1994, increasing their floor space from 5,000 to 20,000 sq. ft.

Today, GP Precision provides design engineering and production services for the telecom, medical, computer, fiber optic and audio markets with prototype and JIT monthly blanket orders. Parts are supplied complete, including plating, painting, silk screening, assembly and packaging. They have built their reputation on the quick turnaround of high quality parts in aluminum, steel, stainless steel, brass, copper and plastics. Their ability to keep up with this growth is attributable to how they’ve applied new punch press technology as it has become available.

GP Precision’s capabilities include shearing, punching, forming, deburring, welding, spot welding, and hardware installation. The key to their success, according to owner/president, Art Cubbage, is the use of computerized equipment to process jobs quickly and accurately and limit downtime. GP Precision can produce 5,000-piece runs in three-to-four weeksin just about half the time it takes the majority of their competitiors. Prototypes are often produced in as little as a day. Much of their ability to respond quickly has been provided by the use of CNC punch presses.

GP Precision’s original move toward automation was a Super 30/30 from Strippit, Inc. (Akron, New York), a semi-automatic hole punching machine that is still in use today for less demanding applications that do not require a turret press. In 1984, the company purchased its first CNC punching machine, a Strippit CAP 1000. This computerized machine quadrupled their output. The amount of work they could do in 70 hours on the Super 30/30 could now be done in two days on the CAP 1000. “This enabled us to take more high volume jobs,” Mr. Cubbage says. It also necessitated the move to Hackettstown, so they would have room to handle the increased work load.

In 1992, they purchased their first 1000R CNC turret punch press (now called the 1000/20). Although the running speed on the 1000/20 was the same as the CAP 1000, the new machine offered faster set-up times because of the high-speed turret design and new features like auto indexing. This allows tools to be rotated via the computer control so that the machine can punch more with fewer tool changes. The 1000/20 also features multi-tool, which increases the tool-carrying capacity of the turret.

In 1993, GP Precision purchased a Strippit 1000 XP/20, which provided “50 percent more output in the same floor space,” Mr. Cubbage says. “This was very important in our old building because there was limited space.” In 1994, they added another 1000 XP/20. With axis speeds up to 3350 inches per minute and hit rates up to 330 hits per minute in 11 gauge material, the 1000 XP’s were twice as productive as the 1000/20 press. Once again, GP Precision found themselves having to move to larger quarters to accommodate the work.

Because of the rapid turnaround, GP Precision is now able to help its customers accurately schedule, “Just In Time” deliveries and keep costs down. “We’re much more competitive because the XP is faster,” Mr. Cubbage says. “We can take higher volume jobs now. We were on the outside edge before we got the XP machines. There is a major difference in volume output and improved turnaround. This makes us a better vendor to our customers.”

He is also very pleased with the speed at which his operators were able to learn and use the PC-based controls that drive the machines. Parts are programmed in the engineering department, downloaded via floppy disk to the punch press and modified on the press if needed. PC-based equipment has also proven to be easy to service, according to Mr. Cubbage. “If a hard drive crashes, you simply swap the CPU and you’re up and running,” he says, but was quick to add that in the nine years they have used these machines, they have only had to replace one bulb.

Increasingly capable punching technology has helped GP Precision increase their productivity from average lot sizes of 70 parts 10 years ago to averages of 250 today. The company plans to add another Strippit punch press within the next year to help them keep up with the work volume and maintain their rapid turnaround. “Most of our competitors have a six-to-eight-week turnaround,” Mr. Cubbage says. “Our normal turnaround is three-to-four weeks.” The technology enables them to do that.

http://www.mmsonline.com/articles/0596bp5.html

punch press from LVD (UK) is helping BAe Systems in building a new class of nuclear powered submarines

Building a nuclear submarine is a complicated business - not least when it comes to the sheet metal components. The confined space and curved walls of the interior mean that many items, such as lockers, bunks, kitchen equipment and ducting for heating and ventilation have to be made as one-offs to fit the space available.

The bae systems shipyard at Barrow has just launched HMS Astute, the first of a new class of nuclear-powered hunter-killer submarines for the Royal Navy, and is now building the next two boats, with a fourth on order.

An LVD Global 20 CNC punch press is providing the capability and flexibility to ensure that all the sheet metal requirements for these vessels are met in a timely and cost-effective way.

Colin Taylor, Outfit Manufacturing Manager at the Devonshire Dock Hall in the Barrow yard, is in charge of the sheet metal shop and explains how complex the job is.

‘There are something like 8,000 different bits of equipment on every submarine that have to be fabricated from sheet metal - as well as about 1000 metres of heating and ventilation ductwork.

For items such as the lockers we have to design and manufacture units of the right size and shape to fit into the available space.

It isn’t like a surface ship where you can use standard units.

And it is the same on the ducting.

Whereas on a normal contract you would expect to have long straight runs, on a submarine every ventilation spool is different.’ Even if the submarine needs a number of similar components it is unlikely that Colin will be able to schedule them to all be made at the same time.

Everything has to be delivered just in time for installation as the boat is constructed - deck by deck and module by module.

‘You have to make what they need when they need it,’ he says.

‘We make a wide diversity of parts and use a lot of different materials - aluminium, stainless steels, mild steel and galvanised steel - in thicknesses up to 3mm on steel and 6mm on aluminium.

And while somebody making PC cabinets or washing machines is making thousands of the same part, we might make a single locker in mild steel, then run half a sheet of aluminium and then move on to something else.

It can literally be one-off after one-off after one-off.

And although we try to plan like with like, we may change the material on the machine eight times a day,’ says Colin.

This requirement for total flexibility was the driving force behind the decision to replace an existing punch press with the new LVD Global machine.

The Global installed at Barrow is a 20-tonne hydraulic, thick-turret machine with thirty tool stations.

The tool capacity is expanded by the use of multi-tools in two of the three rotary stations.

These hold eight tools and three tools respectively, with each tool able to be individually rotated.

Overall, this gives a total of 39 tools in the turret at any one time, of which twelve are fully indexable.

‘Around 80% of what we produce in the sheet metal shop goes through the punch press; it is at the heart of our production so it has to be very productive.

And to be productive it has to be very flexible.

‘We were doing massive numbers of tool changes on our old machine because of the variety of materials we are using.

Now we have a bigger turret with more tools so we have been able to optimise the tooling configuration for the type of work we are doing.

For example, we have some common tools duplicated around the turret, but set up with different die clearances for different materials.

This new flexibility means that we only have to change the turret configuration a couple of times a day.’ The Global has also allowed BAe Systems to use new manufacturing approaches to refine its designs.

Form-working, in particular, has allowed it to reduce secondary operations and assembly time.

As Colin stresses, ‘We aren’t a first generation user going from making a locker by hand to using CNC.

We are going from one CNC process to a more sophisticated one.

Now we want to explore how we can refine our designs to such an extent that we are really using the machine’s capabilities.’ At its simplest level this is represented by the use of a centre-dot marking tool to identify every part with a unique product number - previously this was done by hand using a marker pen.

At a more sophisticated level, the use of semi-shear tool allows parts to be snapped together without rivets, and a hinge-making tool can form the hinge from the sheet - whereas before the hinges were also riveted on.

‘We have made a lot of modifications to the locker doors, for example,’ says Colin.

‘We used to rivet the outer and inner skins of the door together, now the semi-shear tool means we can just snap the parts together.

And with the hinge-making tool, the only secondary operation required is to slide the hinge-pin into place.

We are saving a lot of time by not using rivets.

By using technology to take out manual second operations the standard manufacturing time for a finished locker has been cut from eight hours to five hours.

And if we have to we can manufacture a locker from start to finish in about 2 1/2 hours rather than the seven hours it would have taken us.

Finally, in making the switch to another machinery supplier Colin comments ‘Whilst there was the normal learning curve that you would expect with implementing any new technology into the workshop, LVD’s back up and response has been excellent, when we have needed help either on the phone or a visit to site the response has been first class’.

http://www.manufacturingtalk.com/news/lvd/lvd171.html

Semi-automatic and automatic punch presses shear right angle profiles and strip, positioning them first using a material tracking system - all operated by touch-screen CNC

Geka, Spain, has introduced the C2PL - an automatic punching and shearing press - or steelworker - for processing angle angles, from 40 up to 80mm in ‘L’ profile. There is also the semi-automatic SEMI-PAXY to solve the problem of material positioning before punching flats and profiles. * Geka C2PL - has a material tracking system, two punching units (one for each leg of the angle) with a fixed back mark (manually adjustable on an easy way) and a shearing unit, all of them controlled by a CNC with a touch screen.

Companies needing to process large amounts of small angles are going to find a fully automatic and really productive solution in the C2PL at a very reasonable price.

It takes less than 2s to make a punching or shearing operation.

With these new models Geka increases its machine range for working with thick material, market where it continues being the worldwide leader.

* Geka SEMI-PAXY - the positioning of the stops is completely automatic and it is programmed from the control.

Geka has also developed the GekaPro-PC positioning control that runs the Semi-Paxy table.

It is a windows based control with a touch screen where the operator can design the parts he wants to process.

It is a visual and a very easy to use solution.

Among its applications, there is the possibility of importing DXF and DSTV files, saving a lot of time on the designing process.

Geka at EMO 2007, Hannover, Germany, September 17-22, Hall 14, Stand C30.

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Designed to verify and restore angular alignment of turret press punching stations, Pilot(TM) Tool Calibration System consists of matched set of upper and lower interlocking components loaded into machine’s turret upper and lower chambers. It operates in Verification and Alignment modes and features tri-color indicator lights to warn when system is not aligned, aligned angularly and concentrically within 0.012 in., or aligned angularly and concentrically within 0.0003 in.

Anoka, Minnesota: Mate Precision Tooling leads the punching industry with another “first” - the Mate Pilot(TM) Tool Calibration System. Designed to verify and restore the angular alignment of punching stations of a turret press, this system is highly accurate and easy to use.

The Pilot Tool Calibration System provides punch press users with an effective and reliable means for maintaining top punch press performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.

System Ensures Precision Concentric And Angular Tool Component Alignment

Consisting of a matched set of upper and lower interlocking components, which are loaded into the machine’s turret upper and lower chambers, the system operates in two modes:

Verification mode - Confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life.

Alignment mode - Restores the concentric and angular alignment of each station with the same precision as the initial machine installation.

System Is Easy And Fast To Use

Simply install the two halves of the calibration instrument into the press turret station to be aligned. Then rotate the turret to position the station to be aligned under the machine’s ram. Tighten the integral adjustment handle which draws the two halves of the calibration instrument together.

As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.

During this process, tri-color indicator lights on the top of the instrument signal alignment. When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012 inch / 0.030 mm; Green - system is aligned angularly and concentrically within 0.0003 inch / 0.008 mm (recommended when punching materials 0.078 inch / 2.00 mm thickness or less).

High Precision Components Ensure Accuracy, Long Life

Like Mate’s high precision, long-life tooling, the Mate Pilot Tool Calibration System is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance. Each calibration instrument is machined from a single piece of the highest quality tool steel. Upper and lower halves of the instrument are separated near the end of the production process and just prior to the installation of hardware. This ensures that the two components are a precisely matched set with high accuracy, thereby eliminating any possibility of cumulative tolerances adversely affecting instrument accuracy.

Mate Pilot Tool Calibration Sets Available For Amada And Finn Power Presses

Mate Pilot Tool Calibration sets are available for Amada thick turret and Finn Power presses in: A Station 1/2 inch (12.70 mm), B Station 1-1/4 inch (31.80 mm), C Station 2 inch (50.80 mm), D Station 3-1/2 inch (88.90) and E Station 4-1/2 inch (12.70 mm). Accessory kits consisting of alignment and adjusting bars are required that work with any station size.