Emerging and Versatile Solutions in Tube and Pipe
Major productivity increases when it comes to tube and pipe fabrication processes open the door to new opportunities. The post Emerging and Versatile Solutions in Tube and Pipe appeared first on Fabricating & Metalworking.
Learn about the latest advances in tube and pipe fabrication machinery that supports your shop in manufacturing quality, superior products.
New All-in-One Tube Processing Solution
HSG Laser (Addison, IL) introduced the TPSD Series, an all-in-one tube laser cutting solution. The TPSD combines cutting, tapping, and drilling in one compact, efficient machine. Designed for industries such as fitness equipment, furniture, and job shop manufacturing, it accommodates tube sizes ranging from 0.47”-to-10” in diameter.
The TPSD Series features intelligent automation, delivering precise and efficient processing to help manufacturers reduce material waste, production time and labor costs. It is also versatile, providing a cost-effective approach for handling complex geometries with high precision.
The TPSD offers maximum efficiency by allowing users to merge cutting and drilling processes into one seamless operation, which significantly speeds production. Laser-powered thermal drilling enhances overall product quality. Plus, by reducing the need for multiple machines, the integrated TPDS solution lowers costs. Easy-to-use features reduce training time and streamline manufacturing processes. Non-contact laser technology ensures no mechanical stress or deformation, preserving material integrity.
Automated 6-axis Structural Steel Robotic Beam Cutting Machine
Machitech Automation (Saint-Marc-des-Carrieres QC) recently updated its Beamcut BC25. The BC25 is a user-friendly, versatile, robotic 3D CNC cell and platform for cutting metal parts and profiles from mild steel, stainless steel, and aluminum for virtually any structural steel shape. With high-definition Hypertherm plasma technology and FANUC robotics, the Beamcut BC25 is a totally automated 6-axis beam cutting system that provides maximum optimization of the manufacturing process, improving overall repeatability and accuracy while eliminating bothersome layout work before cutting, and time-consuming and costly grinding after profiles are cut.
Along with an automated in-feed and out-feed system on a smaller footprint, the BC25 has unique features, including a Photo-Laser Measuring Device that allows split-second profiling and positioning to guarantee a precise cut. There is an advanced Windows-based Operator Control System that is easy-to-use and does not require special operator training. Proprietary Beamcut Soft software utilizes DSTV files from 3D profiling software and 2D DXF AutoCAD files. Once files are imported, Beamcut Soft automatically simulates the cutting sequence. An automatic cutting trajectory is created and verified on the drafting computer instead of the machine. The BC25 incorporates a safety enclosure and smoke trap that delimits the space required for robotic cutting and the circulation area around the system. A safety cabinet complies with OSHA safety standards. An optional dust collector is available to remove smoke and dust particles.
Abrasives Offer Unprecedented Grinding Performance
Saint-Gobain Abrasives’ (Worcester, MA) Norton RazorStar fiber discs, quick-change discs and belts feature innovative engineered shaped ceramic grain, a breakthrough technology with unbeatable performance even in the toughest grinding applications. A unique combination of razor-sharp grains with a supersized grinding aid helps to significantly reduce heat generation for cooler cuts and longer life on a range of materials such as carbon steel, aluminum, stainless steel, nickel alloys and other hard-to-grind metals.
“We are seeing an up to 50% cutting performance improvement compared with other ceramic discs on the market today, and we are very excited to offer our customers new abrasive discs that will take their grinding performance to a new level of efficiency when removing welds, grinding, beveling and doing heavy deburring,” said Jeremy Spencer, product manager, Norton | Saint-Gobain Abrasives. RazorStar Belts, which are designed for medium to high pressure metal removal in challenging robotic or off-hand applications, are producing the same number of parts with fewer belts and less machining and changeover time, while consuming less energy, said John Benkoczy, senior product manager, Norton | Saint-Gobain Abrasives.
New Tube Grinder with Built in Dust Collection System
Scotchman Industries Inc. (Philip, SD) offers the new SG3 Industrial Belt Grinder, which features a unique built-in dust collection system for efficient, heavy-duty grinding. Equipped with a robust 4.1 hp motor, the grinder provides consistent power for quickly deburring as well as sanding small and large parts, making it ideal for metal fabrication and production environments. The integrated dust collector helps to create a clean and safe workspace. This grinder is built with durability in mind, providing reliable, quiet performance for professionals seeking high-quality metalworking equipment. The SG3 Grinder features rapid material removal without vibrations while the contact wheel provides a safe and consistent grinding area. The grinder also features a top grinding table for increased versatility. Plus, the grinder has multiple adjustment features to accommodate operator preferences and varied material options, including adjustable working height, adjustable tool rest and adjustable eye shield.
Fabricators will value the SG3 grinder’s ability to reduce grinding time. Its tool-free belt change system allows users to quickly match the abrasive material to the required finish and application. Additionally, the flexible contact wheel extends belt life, while the tool-free belt tracking adjustment saves time during operation.
Tool Line Takes Bite Out of Tube End Finishing
For manufacturing of tubing products, or those who manufacture products with tubing components, Severance Tool (Saginaw, MI) has developed a line of tube end finishing rotary tools which can deburr, form, or chamfer as required by application needs. The tools are designed to finish both the inside diameter and outside diameter of tubing ends in a single operation and many feature adjustable, two piece construction to accommodate work on same size tubing having varying wall thickness ranges. Other features may include, depending upon application, Chatterless
tooth geometry that alternates tooth-cutting angles to eliminate resonant vibration from the tool and work piece for smooth finishes, and Severance’s exclusive Grayhone finish that provides cutting edges ready to work with no break in period required. Among the tools offered is a full line of tube deburring tools available in high speed steel or carbide construction. These tools, although they provide a 30° inside chamfer and a 45° outside deburring, are designed for light duty — to break sharp edges of both the inside and outside diameters simultaneously. They feature tooth geometry with a shearing cutting action for fast cutting that prevents loading of chips. These tools can be reground numerous times for long service and operate in speed ranges of 50-to-200 rpm. The outside ring or member is adjustable, secured by screws, to provide various outside edge break sizes and compensate for different wall thickness within a given tube diameter range. Tube deburring cutters are available in standard sizes for 1/8” outside diameter (1/16” inside diameter) through 2-1/4” outside diameter (2” inside diameter) tubing, and with a variety of shank styles. Adjustable as the deburring cutters, plus with Chatterless angle geometry are designed for heavy duty cutting to machine precise, smooth 45° outside diameter and 30° inside diameter chamfers in applications requiring easy assembly with other components. Chamfering mills are available in sizes for pipe and tubing ranges from 3/16”-to-2-1/2” outside diameter. The tube end forming cutters machine both an inside diameter and outside diameter radius, establishing a smooth, rounded end that is ideal for applications where tubing may be exposed. A selection of high speed steel and carbide tools are available in sizes for tubing ranging from 1/8”-to-2-1/2” outside diameters — each outside diameter size is complemented by a range of wall thickness or gauge sizes to accommodate the most popular tubing applications.
New Automated Unloading System for Laser Tube Cutting
TRUMPF Inc. (Farmington, CT) offers a new automated unloading system for its laser tube cutting machines. Laser tube cutting machines equipped with the “automated unloading interface with longitudinal belt conveyor” can automatically convey cut tubes to an automation system, which then sorts the parts or delivers them to the next production step for further processing. The automation solution, which is designed to prevent errors and reduce the operator’s workload, is available for TRUMPF’s 5000 and 7000 series TruLaser Tube laser cutting machines.
“Laser tube cutting involves a high operator workload, which can be very challenging for many companies,” said TRUMPF Inc. Executive Vice President Burke Doar. “Our solution helps companies tackle the shortage of skilled workers while also improving capacity utilization. The result is higher productivity and greater competitiveness.”
In machines equipped with the new solution, the laser cut tubes are automatically deposited on a belt conveyor. The conveyor transports the parts to the automation system’s safety enclosure. Here, the parts are retrieved by a separate machine known as an integrator, which could be a robot or some other handling device. TRUMPF uses integrators from well-known partners, such as Starmatik and Transfluid, for part retrieval and handling.
None of the automation obstructs or limits the open concept of the laser cutting machine: users are still free to unload parts manually, an option that continues to be particularly advantageous for small batch sizes and intermediate products. TRUMPF’s automated unloading system also features a digital interface that transfers all relevant information about the parts to the integrator. TRUMPF’s Programming Tube software makes this data available to the integrator automatically via the TruLaser Tube’s digital interface. This data makes the next stage simpler, for example by enabling the Starmatik robot to sort cut parts or convey them directly to the next step in the process without having to teach individual positions. This digitalization solution also saves time and reduces the possibility of errors.
TRUMPF’s automated unloading system is a particularly good choice for medium and high-volume manufacturers, as well as for job shops that handle orders of various sizes. Typical applications include furniture, fitness machines and agricultural machinery.
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