Metal Forming Essentials: Shaping Metal with Precision and Efficiency
Navigate complex metal forming processes by leveraging the latest advances in machinery. The post Metal Forming Essentials: Shaping Metal with Precision and Efficiency appeared first on Fabricating & Metalworking.
With easy-to-use interfaces and a focus on automation and robotics, precision and increased power, metal forming systems, including ironworkers, bending, plate rolling and punching, conquer challenging applications with streamlined solutions.
High-Precision Press Brakes with Automatic Tool Changers
AMADA AMERICA, INC.’s (Buena Park, CA) HRB ATC Series is equipped with the manufacturer’s patented Automatic Tool Changer (ATC) — making it the ideal solution for variable lot sizes and the seamless introduction of rush jobs. Achieve even the most complex tool setups in four minutes or less with the ATC. To expedite delivery to North American fabricators, the HRB 1003/2204 ATC Series is manufactured at the Carolina Manufacturing Center in High Point, N.C.
Two models are available in the HRB ATC Series — the 110-ton, 1003; and the 243-ton, 2204. The HRB 1003 ATC, for instance, loads the most complex tool layouts within four minutes. AGRIP-A punch holders lock via AMNC 3i control to reduce setup time. The double clamp backgauge provides stable processing of complex parts. “Lite Mode” allows operators of all skill levels to create bending programs quickly. Automatic foot pedal slides to the next bending position to improve efficiency. Optional sheet followers ensure one operator can safely and efficiently process large parts. The Bend Indicator Sensor ensures accuracy and eliminates trial bends. The L-Shift function processes asymmetrical workpieces easily.
The high-precision HRB Series leverages industry-leading bending technology, the latest generation of intelligent controls, and a variety of production-enhancing features to resolve your bending challenges.
All-electric Tube Benders Handle Challenging Bends
BLM Group’s (Novi, MI) all-electric tube benders, the E-TURN52, ELECT102 and SMART, offer speed, quality and extensive capabilities. E-TURN offers versatility, high quality and efficiency through its left- and right-hand in-process bending functionality. Fast and efficient, the machine can make even the most challenging parts in a single work cycle with high repeatability and quality bends that get the part correct from the start. Simple for operators of all experience levels, this machine is designed to be reliable, safe and easy to use to keep the machine always operational.
The SMART utilizes nine electric axes to perform left- and right-hand fixed and variable radius bends with single or stacked tooling. The loader can be installed on the left or right side of the machine and is entirely self-sufficient for automatic operation. With automated load and unloads via proprietary swing-head design, the system is an automated solution for metal tubes of any material type, hybrid tubes with flexible elements and pre-assembled tubes with formed ends.
The ELECT is a configurable, reliable and powerful bender that is robust, fast and efficient. It is ideal for integration in an automated manufacturing cell. Capable of performing fixed and radius bends on tubes with any cross-section, this machine provides unlimited possibilities even for end-formed and flanged tubes. This machine is also designed to reliably pump out accurate bends for high repeat parts.
New Laser Measuring System Adds AI to Plate Rolling
Davi, Inc. (Addison, TX) has developed the iVision laser radius measuring system for its e-POWER fully electric machines that brings artificial intelligence (AI) to the plate rolling process, making it significantly simpler and giving shops the ability to run machines unmanned.
With the combination of AI and a specific algorithm, iVision encompasses reading/measuring and self-correction through the e-POWER fully electric machine’s CNC to automatically adjust in real time. This streamlines the rolling process and ensures the most accurate results in the shortest amount of time possible.
In a typical rolling process, operators will load a plate and start rolling. As the plate is rolled, they manually check its radius with a template, then return to the control, make the adjustment, advance the plate further and repeat the procedure until the desired radius size is achieved. This back-and-forth procedure can happen several times during a single plate rolling sequence. Because iVision eliminates the need for templates, the system not only speeds the process, but it also significantly reduces the need for highly experienced operators to make those manual adjustments.
Unlike other similar systems, iVision uses a “laser blade” as opposed to just a single laser beam point. The laser blade scans a wider rounded area, taking thousands of points along the curved surface of the radius at one time. When systems use only one laser beam point, there is a risk that material surface mill scale and other shop environmental conditions such as light reflections could negatively affect the measurements.
The iVision’s laser head also moves up and down in the vertical axis as well as tilts. Such capability ensures that the laser blade is always in the ideal position for measuring the radius regardless of its size. Once a measurement is taken, the system sends the reading point data to the e-POWER fully electric machine’s CNC that then quickly makes the required side roll adjustments in real time.
Davi also offers the iVision system in another version called iRadius that simply provides the measurement in a digital readout for operators themselves to make the necessary adjustments when running machines without CNC controls. The iRadius unit is retrofittable to existing machines and is especially useful for those shops rolling extremely large parts that would otherwise require the operator to crawl inside the parts to take measurements.
Bending Machine Automates Complex Technical and Bending Parameters
HSG’s (Addison, IL) HC Electro Hydraulic Servo Bending Machine automates complex technical parameters; including bending force, main motor power, rapid descent and working speed, the number of CNC axes, equipment weight, and fuel tank capacity. It utilizes a Netherland DA-53T control system to automatically calculate, compensate, position and correct bending parameters; integrates an automatic compensation system for mechanical deflection; has a backgauge positioning system; and offers users an optional bending follow-up trolley. This bending machine is constructed on a highly ridged heavy-duty frame.
The machine’s Netherland DA-53T control system automatically calculates and corrects bending angles and backgauges, makes mass bending possible, and delivers main pressure and deflection compensation programming. The control system also enables wireless interconnection via desktop or notebook computer.
The HSG Bending Machine’s automatic compensation system for mechanical deflection controls bending station movement laterally and vertically; calculates compensation based on length, thickness and angle of bending workpiece; and takes accurate control of compensation precision by way of a high-precision potentiometer.
The bending machine’s backgauge positioning system utilizes servo motor drives to move backward, forward, up and down. The backgauges can extend to four axes or six axes for easy bending. It has a positioning system that can configure four positioning fingers to prevent materials from sagging and defects caused by any error.
Diverse Lineup of Plate Rolling Machines
KAAST Machine Tools, Inc. (Aldan, PA) offers a diverse lineup of five models of plate rolling equipment: the RBD-3M, the RBD-3HL, the RBD-4H, the RBD-4HD, and the RBD-4HL. The RBD-3M is a plate roll series designed for light to medium jobs, accommodating materials up to 10 gauge in thickness. Applications include creating aluminum bendings, air conditioning channels, advertising panels, and sheet metal covers. This series of plate rolls is offered in 3’-to-6’ lengths and features top rolls fixed via a locking lever, with adjustable side and bottom rolls. Each model includes wire grooves on the bottom rolls and left-right rotation on the dual footswitch.
The RBD-3HL plate roll series is intended for medium and heavy bending tasks. The frame is constructed of solid, welded steel, with all rolls mated to high quality, heavy duty bearings, ensuring minimum friction and even rotation throughout the bending process. The hydraulic rollers are driven by independent drive motors and planetary gearboxes. Available lengths are 6’-to-13’ and can accommodate plate thickness between ⅛”–to-⅝”.
The RBD-4H series rollers are heavy-duty plate rolls, accommodating the needs of a variety of businesses, including shipbuilding, trucking, wind-power, and construction sectors. The four rolls of this hydraulic plate bending machine are equipped with high-quality, heavy-duty ball bearings, ensuring minimum friction while assuring even rotation of the rollers. The RBD-4H series accommodates 14 gauge 3/8” plate thickness and is available in lengths between 2’-to-13’.
The final series of plate rolls include the RBD4HD/4HL hydraulic plate bending machines. These state-of-the-art bending machines are ideal for medium and heavy bending tasks, featuring a solid, welded frame, a hydraulic roller driven by an independent drive motor and planetary gearboxes. Torsion bars work simultaneously with hydraulic units to ensure maximum machining accuracy, while accommodating production flexibility. The RBD-4HD/4-HL is available in lengths between 6’-to-13’ and accommodates workpieces between ½”-to-1-3/4”.
50-Ton Ironworker Features Quick Change Punches For Repetitive Operations
The Scotchman Industries’ (Philip, SD) 5014-ET 50-Ton Ironworker features a three-station revolving turret that accepts up to three different punch sizes, changeable in seconds, reducing setup times and increasing productivity.
The 5014-ET hydraulic ironworker is a single operator design with seven total stations. It features 50 tons of pressure and has the ability to punch a 13/16″ hole in a 3/4″ plate. It comes standard with an angle shear capable of shearing 4″-x-4″-x-3/8″ angle iron, a flat bar shear that can shear 3/4″-x-4″ to 1/4″-x-14″, and rectangle notcher for notching up to 2-1/2″-x-3″ in 5/16″ material. Standard electric stroke control makes the 5014-ET machine very accurate for bending, punching, shearing and notching operations. A remote foot pedal and punch slug receptacle are additional standard features.
With its component tool table design, the 5015-ET has the ability to accept optional equipment such as a 12″ press brake, rod shear, square tube shear, picket tools, and pipe notcher, greatly expanding fabricating capabilities. Custom tooling to meet unique sizes or shapes is also available. The 5014-ET ironworker is proudly made in the USA and is backed by Scotchman’s three-year warranty.
Precision, Power, and Support: The LEMAS TR and 4TR Series
In metal fabrication, efficiency and reliability define success. The LEMAS plate bending rolls, exclusively distributed by Trilogy Machinery (Belcamp, MD), exceed industry standards with durability, and extensive support. With more than 1,200 LEMAS machines in operation across the United States, they have proven their value in shops nationwide.
The LEMAS TR Series is a three-roll initial pinch plate bending roll, handling materials from 3’-to-10’ in length and up to 5/8-thick. Operators achieve repeatable results with a digital readout for the hydraulic rear bending. The lower pinch roll features a hydraulic adjustment and quick pinch-gap setting device. Hydraulic tilting enhances cone rolling, and the direct-drive system eliminates belts and chains, reducing maintenance.
The LEMAS 4TR Series is a four-roll double-pinch plate bending roll for more advanced applications, delivering enhanced control and efficiency. Multiple digital readouts, hydraulic adjustments, independent pressure settings, and tiltable bending rolls make these machines versatile for diverse rolling needs. A console panel on wheels further adds to the ease of use.
Both series of Lemas Plate Bending Rolls feature heat-treated rolls for longevity and Sumitomo Cyclo® gear-less speed reducers for superior performance.
Trilogy Machinery, based in Maryland, and its nationwide network of local dealers support its customers beyond the sale, providing a complete parts inventory, trained technicians, and lifetime technical support. LEMAS is committed to your success, which is why the machines boast the best plate-rolling warranty on the market – two years for parts and one year for labor. A wide selection is in stock at Trilogy’s facility, ready for immediate delivery.
Easy-to-use Press Brake Launched in U.S. and Canadian Markets
TRUMPF Inc. (Farmington, CT) has introduced a new and attractively priced press brake for U.S. and Canadian companies entering the metal bending market. Featuring the new Right Angle (RA) control system, the TruBend 1000 is extremely easy to program. Operation is similarly straightforward – thanks to the user-friendly interface. The TruBend 1000 is available with press forces ranging from 66-to-353 tons and bending edges from 6.6’-to-13.1’. It can be used to produce a broad spectrum of bending parts.
“Like all new entry-level machines from TRUMPF, the TruBend 1000 is precisely tailored to the needs of companies looking to break into metal bending,” said TRUMPF Inc. TruBend Product Manager Chris Wargo. “The machines are every bit as robust and reliable as our high-end models, but at a much lower price tag. We can now provide even more solutions to help companies grow and manufacture competitively.”
TruBend 1000 Series customers benefit from the latest digital technology and TRUMPF services. If any questions or issues arise, TRUMPF technicians can connect with the machine online and provide customers with remote support. The TruBend 1000 has features designed to meet the needs of companies getting started in metal bending. The press brake comes with the proven TRUMPF tooling
clamp and is compatible with TRUMPF bending tools. In addition, users have access to a demo version of TRUMPF’s offline programming software TecZone Bend. This means the machine can be programmed from the office while in full operation, to increase productivity even more.
The TruBend 1000 is suitable for all companies that manufacture simple and semicomplex parts in small to medium batch sizes. This model comes with the TRUMPF tool system and is suitable for small batch sizes, as tool changes can be done quickly. The press brake is attractive for smaller companies or contract manufacturers operating in single shifts. The first machine available in the series has a capacity of 165 tons and 10.17’ of bending length. Further machine sizes and bending lengths will follow.
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