Wednesday, 20 April 2016

Compact CNC full-electric press brake BOXER

We would like to represent for you the full electric compact press brake BOXER with 25 tons force for precision bending of compact parts. The machine is equipped with powerful ESA control, 3 full-controlled CNC axes and many comfort features like side tables for raw materials and final parts. This press brake has compact dimensions to install in every workshop and to divide the work between the massive machines to save the power and environment. Advantage of main servodrive instead of hydraulic unit is to reduce the maintenance and increase precision of bending. English and German languages are installed, others under request. Standard bending tool system is Promecam but WILA-Trumpf holders could be installed as well. All components from well-known brands and the possibility to work while sitting to reduce fatigue of operator during the working day. Any bending tools could be supplied under request.

Sunday, 13 March 2016

Punching or laser cutting?

When there is only the start for sheetmetal fabrication one of the main question is what technology and equipment to choose - punching or laser cutting?

Both technologies are very well known for dozens of years. Moreover, around 30-20 years ago there were models of machine tools to include both cutting processes in one machine. Punching is the key for speed and productivity. Laser cutting is the possibility to cut everything on the sheet and to make the complicated contours of the part.

From one side punching is more complicated. First, you are tighten with punching tools for your machine and can produce the geometry only according to the tools you have in your stock. Second, you are limited with the machine force and hole size - standard machine with 20 tons of punching force is limited with big sizes because of the max. force to obtain. Third is the material thickness. Normally punching is good for 2,3, maybe 4 mm. If you have sheets thicker you need to calculate forces, study the possibility to run 30 or maybe 40 tons of punching force and look for the clamps because they are limited with max. possible weight of the sheet to proceed.

For the second side you have the maximum possible speed because it is very complicated to find other technology to compare with speed for modern punching press. There are really impressive details like 1800 hits per min for nibbling, just try to imagine!

And from the third side is the investment for your new machine as important part of study. Modern CNC punching machines with good brand names are very expensive for sure. But together with them and speedy turret punch press with 30-50 stations there are more simple, less expensive 1-station Multitool punch presses or even semi-automatic solutions. So let say for example, if you look for the turret punching press you can count more than 200 000 EUR, you can study Multitool machines with the prices less than 100 000 EUR. For sure the range of prices is very approximate because we do not sell punching presses.

With laser for sure you will have other details.
First, no tools and you are free to cut everything you want. In this case, besides of your company products the laser is the possibility to run in jobshop - you can cut any part you need without the necessity to order any tooling for any holes.
Second, thickness is the question to the possibility of the laser source but can be 10, 15, even 20 or more mm. So you can cut really thick parts which are impossible to standard punching. Moreover, standard laser table holds the sheet without the movement - it means that there is no clamps and question to the weight of the part.
Third thing that investment could be much more than for punching. But in return you will have the flexibility with the process and there are solutions even for big parts like for example 6 meter long parts. There are no punch presses to realize it with standard punching models.

But for sure the main answer is your application. If there are straight routes on the part, standard applications like doors, metal furniture, electric cabinets, metal cases for electronic, like PC blocks or servers with standard holes and 1,2,3 mm thickness, it is standard work for the punch and you will loose productivity with laser. If, on the contrary, the question is the productivity, thicknesses more than 5 mm, different figure contours, like pieces of garden art, for example, laser could be better and more close as the solution.
We do not put inside more details about punches and lasers because this is question to the manufacturers at first. Moreover, a lot of manufacturers today produce punching presses and lasers as well so there will be no real competition and you can get the detailed recommendation depends of your main requirements.

How to choose your first tube bending machine

Original source for article

Tube bending - is completely different process with deformation of the material. In case of necessity to initiate tube fabrication in the workshop there are a lot of questions needs to be solved and main of them - how to get the tube bending machine which you need. The question is specific because depends of the possibilities the market offers tube bending equipment from 500 Euro till 200-300 thousand of Euro with lots of automation actions. For sure you can start as well with handy tool if the question is single repair of small tubes and there is really no any need of the machine.

The general question to start is the application and requirements. If the tube is thick, no any necessary requirements and precision, the application doesn't connected with high pressure liquids and production time is not important there is no necessity to look for mandrel or even automatic tube bending machine.

There are different mandreless small or even big machines for tube bending without use of mandrel. In general the process is the same as original draw tube bending - the radius of the tube is formed with the size of the bending die which is installed on the machine. Mandreless tube bending means that there is no additional mandrel and normally the machine is very simple without any feed of the tube and only with rotation of bending die driven. This solution is cheap, gives good quality if bend is not hard and could be very profitable when there are simple applications, like furniture, water tubing, fences, road barriers, outdoor equipment etc. Moreover, with mandreless tube bending there is serious limitation that the bending is normal with the radius around 3x outer diameters or tube.

Simple tube bending machines and equipment is very important with small series bends, garage fabrication, repairs etc. No any automatic machine could be transferred on other place so with on-place repairs or various and simple applications madreless bending could be the best way. Tube bending technology is usually drived by automotive sector - the production there is very high and tubes could be very complicated. In other way automotive sector drives also the use of simple tube benders - to make railings and bulbars for cars and for example, in USA this is application number one for simple tube bending machines.

If the radius is smaller, tube has thin walls, tube has several bends, the production time is important, quality and precision are critical - these things could be performed only with mandrel tube bending machine. There are so many applications where mandrel tube bending machines are normally used: from furniture and simple fences until the tubing for high pressure liquids, like hydraulic tubes, automotive industry, energy, heating, aerospace… Mandrel tube bending means the possibility to install the mandrel inside tube during bending - this helps to prevent hard deformation of the tube and inside corrugation at the area of bend. Mandrel tube bending machines could be also totally different - from simple machines where everything is adjusted manually and only bending arm to rotate the bending die is driven until the fully automatic tube bending machines with CNC control, high speeds and integrations with transfer systems and automatic cells. Today the market offers fully electric machine with all movements by servodrives and highest precision for complicated applications. For sure the price of such machinery is also very expensive and the customer needs to know exactly what is the reason to use of high level technology machine or it is better to view more simple solutions.

Thursday, 10 March 2016

Something about CNC tube and pipe bending machines

Image from website of Current Tech - developer of CNC controls and software interface for tube bending machines

What is so hard with complicated CNC tube and pipe bending machines? A lot of people even in production facilities think that it is black box and new technology for everyone. Really yes - tube bending is a hard process if you need to make thin walled tube on manual bender and give the perfect quality - you need to be a guru to follow hard applications with simple technologies.
But in the way you understand that you production program is really big to work with manual equipment and your tubes are complicated with several bends to measure the next bend with simple machine, so in other words, you are ready with reasons and investments for CNC tube bending machine - the rest you need to think is to verify the proper tube bending tools for your applications and CNC bending interface.
Modern CNC tube benders are really very friendly with the user. If you understand how the tube is positioned in 3D and can read the positions on the drawings the creation of tube bending program is the question of seconds. There is no really programming in modern software so software shell let you choose necessary parameters, tube requirements, data of tooling installed and that's all. For sure, it is simple with simple bends and good machine, for hard thin wall bends and tight radius you will go with more precision, adjustments and setup. But if all is clear it is like a nice toy and even people outside of CNC could learn standard software for couple of weeks. So if you choice is right and software is really friendly you will get the good compensation in time to insert the machine in daily production program.
The next nice step is simulation - software has the main parts of the tube bender included and you can view in real time the virtual bending of your tube. The purpose of it - tube moves together with parts of the machine and tools so operator needs to verify that the will be no hits during the process to the frame, tool and the tube. So simulation is one big important and nice parts of tube bending - just imagine to prepare simulation for other production process. And here is simple - standard tube bending time with automatic machine is about 20-30-40 seconds so you can check the real production time without running of the machine with tube. Simulation today is the part of any CNC tube bending machine and if not, there are several companies to make interfaces for your machine.

Post contains the information of third parties. Please look here for more details.

Wednesday, 9 March 2016

Achievement of radius and the mandrel tube bending

Original source for article

The most important point for lots of bending applications is the achievement of required bending radius with the possibility to avoid the defects of the shape and surface of the part: scratches, corrugations, ribs, different deformations and loss of section geometry such as ovality, curved walls of squares and profiles, big wall thinning etc. In this case the general rule of tube bending is the smaller the radius the harder the bending process itself. Minimal radius for draw bending is normally 1D (1 diameter of the tube) but to perform such bend there are a lot of additional requirements for the toolings, machine possibilities and material type.

Mandrel in general plays the part of filler which was used prior for tube bending process (in some cases sand or special polyurethane was used) with old machines or in manual bending dozens of years ago. The main purpose of the mandrel is to save the internal shape of the tube and to prevent the possible deformation of the material inside. The mandrel repeats the internal diameter of the tube and goes in it to be present inside the tube during the bending act. Mandrels have a different execution with additional balls for the possibility of bending itself inside the tube. Selection of the suitable mandrel execution is the normal part of bending tooling set selection. Mandrel is not just the filler to move into the tube but the machine unit with the supplied lubrication system to make easy friction inside the tube and movements. Usually, material of mandrel is bronze but sometimes steel or even plastic mandrels are used.

Because tube bending is the main material deformation, physical specifications of material play the main role with the possibility to make elongation without the hard defects, such as breakage. In this case the bending of soft materials, such as copper, even with small radiuses much more easily than to perform the bending of titanium, for example. Normally, under every task it is possible to make the special calculations to verify the minimum radius based on the material and shape dimensions and to offer the suitable tooling and necessary mandrel execution.

Bending process without mandrel called mandreless and is used on mandreless tube bending machines or with thick wall tubes, not complicated materials with big radiuses and with applications when the bending quality is not so important. Normal general practice that for standard materials normal bends could be done without mandrel if the radius of bend normally is more than 3D (3x diameters of tube).

Don't forget that with us you can request any tube bending tools for CNC tube bending machines. Contact us with your request.

Crossbow tube bending

Image is from Plumbing Web Connection website

Do you know what is crossbow tube bending (somewhere it is also "bow bending or ram bending")? The time is hold between 2 sides and there is force at the middle with installed tool - bend former (or somewhere it also called mandrel nut there is some misunderstanding with the real tube bending mandrel meaning. These formers are interchangeable depends of the bending radius you need. The general requirements for this type of bending is 3-4 OD of tube and normally it is copper today. That is why today on the market in general there are a lot of manual and handy tools with this kind of tube bending. It is very simple but is not good for serious applications. There are a lot of variations and tools but the principle everywhere is the same - force and deformation to the middle, sides holding.
This tube bending process is the oldest one - the idea to bend the tube as it is a beam or other straight part. The same principle somewhere was used with press bending with the press as the source to produce the force. It was also suitable for thick wall application but because of the missing of mandrel and the way of deformation could be used when the surface of the bend area is not important. Also there is the technology for one principle bend because it is very hard to detect the next one.

And it is very interesting to know that half of century ago this technology was used for big tubes as well to proceed with application which today are subject for normal CNC tube cold or induction bending.
This great machine with the name BOXER was constructed by Italian company CRIPPA to bend tubes up to 16 inches.

Image from CRIPPA SpA website

Post contains the information of third parties. Please look here for more details.

Tuesday, 8 March 2016

Punch and die grinder

F-Grinder - punch and die semiautomatic grinding machine for any punching tools for any punching press you have in your turnover - from A to F station of Thick Turret tools or Gr0-Gr3 for Trumpf. And any Multitools for sure. Forget about the necessity of adapters and manual grinding. Check here if you will be interested.
This is list of the machines you can use tools for but it is not complete: Trumpf Trumatic, Trumpf Trupunch, Boschert, Haco, Pullmax , Amada, Finn-Power, Prima-Power, Durma, Schiavi, LVD, Strippit, Danobat, Yawei, Nisshinbo, Euromac, Baykal, FIM, Murata Muratec, Rainer, MVD, Tailift, SimasV, Yangli, Peliant, SNK, Pullmax, Hesse-Maschinen, Ermaksan, Dener, ITEK, SMD etc.