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06/01/2010
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Andrew Allcock reviews recent sheet metalworking equipment installations and highlights latest technology developments
 Washington Metalworks, a sub-contract fabrication specialist based in Tyne & Wear, has installed two Trumpf TruLaser 5030 CNC laser profiling centres with TruFlow 5000 (5 kW) resonators and integrated automation. Representing the first Trumpf installation of its kind in the UK, and the company's first Trumpf purchase, Washington Metalworks has replaced less powerful, 10-year-old technology to quadruple productivity. The machines are linked to a LiftMaster Linear automated load/unload system and TruStore sheet storage unit.
Image: First of its kind in the UK installation at Washington Metalworks
The company scrutinised all of the leading vendors of laser profiling machinery before opting for the 5 kW Trumpf models, which feature a single head cutting strategy and optional nozzle changer to minimise non-productive time on the 3 m by 1.5 m bed.
"Although we selected powerful machines, it was the speed of the technology in cut that provided the differentiating factor," says joint managing director Steve Tate. "For instance, one particular job that previously took 1 hour 28 minutes to complete can now be done in just 23 minutes – a productivity increase of around 400 per cent. What's more, we had many recommendations from within the industry regarding Trumpf technology, while Trumpf also provided an uptime guarantee that other vendors were unable or unwilling to match."
With the commissioning process completed in March 2009, Washington Metalworks was immediately able both to reduce its direct labour input for laser cutting and minimise costly nightshift working." The automation aspect has been a real winner for us," says Washington Metalworks chairman elect Ron Barella. "For instance, using our old manually loaded lasers, changing from 3 mm mild steel to 8 mm stainless steel would take around 30 minutes; now we can do it in just 3 minutes. Overall, the installation has given us the opportunity to be genuinely competitive for laser cutting work, whereas previously we didn't have a chance. As a result, new orders are beginning to arrive."
Elsewhere, at Sotech, a leading manufacturer of bespoke metal rainscreen cladding and architectural fabrications. Demand prompted it earlier this year to treble its production facility, by investing in a new 38,000 ft2 manufacturing plant in County Durham to complement its existing site in the area. Part of this on-going business expansion programme included investment in a Pullmatic 720 automated punching system, equipped with load/unload/parts picking system, twin CNC load cart system, programmable sheet clamps and parts flap and conveyor, at a cost of £490,000.
Richard Eggington, Sotech's operations manager, comments: "We were manufacturing with an older, out of date rotating head punching machine, which was just not able to keep up with the demand. We identified a need to increase our capacity and therefore required a machine that would not only provide us with the necessary speed and accuracy, but which would also be equipped with materials handling in order for us to run the machine with limited supervision for the majority of the time."
The new machine had to be capable of handling aluminium and occasionally thin gauge stainless steel. However, it was the handling system which was of the upmost importance. "We needed a machine which could be left to run unmanned overnight to maintain a steady stream of flat plates to the other machines in the factory. Additionally, the after-sales service accorded by a supplier was going to be paramount to our final decision," explains Mr Eggington.
"We have seen improvement in all production areas – from the way programs are drawn up, to the fact that the machine is generally loaded with up to 100 sheets at a time and left to punch! This has increased our manufacturing capacity enormously," concludes the operations manager.
Box Item
Recent product launches in brief
• US-based water jet specialist Flow International has introduced new technology that improves part cycle time and accuracy by 2 to 4 times, compared to standard non Dynamic systems, and is 30 per cent faster than Flow's original Dynamic technology.
• Called Dynamic Waterjet XD Technology, with its full 3D capabilities it gives manufacturers the ultimate in accuracy, speed and flexibility, says Flow, and it is claimed to be the first high precision 3D cutting technology of its kind.
• Trumpf has announced the availability of a new BendMaster press brakes for large workpieces. This new addition extends this maximum to 100 kg (previously 40 kg) or parts exerting a bearing load of 150 kg.
• The launch of the Gemini by FICEP has created the world's most technologically advanced, multi-functional and flexible system for profile cutting, drilling, machining and scribing, with integral bevelling and an advanced material cutting capability.
• The WARDJet JX-813 waterjet cutting table (Wightman Stewart) has been designed specifically for cutting materials with pure water. The JX-813 can achieve cutting speeds of 63 m/min, with acceleration of 6 m/sec2.
• Hypertherm's HPR130XD and HPR260XD feature Extreme HyDefinition (XD) technology. Chief benefit is more consistent cut quality for longer periods of time, at half the operating cost.
• Water Jet Sweden AB and fellow Swedish company Finecut AB have developed a range of 'fine abrasive waterjet' (FAW) models. The machines offer a reduction in kerf width from the industry normal minimum of 0.5 mm to 0.3 mm on the currently released models, and a potential 0.2 mm.
• Wilson Tool's Dura-Die parting tool with replaceable die inserts offers sheet metal manufacturers a quick, cost-effective alternative to replacing the entire die in parting applications.
• Katlenbach's The KPS 520 is claimed as a world first, hailed as the fastest plate and angle, punching and shearing machine of its type.
First published in Machinery, December 2009
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Author
Michael Richards
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