Profiling technology under the spotlight

Leading subcontractor GU Cutting & Grinding Services has taken its range of value-added engineering services to another level, with the installation of a WARDJet waterjet cutting machine, with full 90° 5-axis cutting capability and Accustream intensifiers, supplied by Wightman Stewart (01422 823801). The installation of this technology means that GU can differentiate its cutting services from other subcontractors and that, as a company supplying services to the aerospace industry, oil and gas, power generation and metalcrafts sectors, amongst others, it represents an investment offering a very high potential return. CUTTING CAPACITY BOOSTED The new WARDJet ZX 2543 2.5 by 4.3 cutting table, together with two matching AccuStream AS 6050 intensifiers, has increased the company's cutting capacity by 50%. The 5 axis machine sits alongside two existing waterjet cutting tables, also acquired through Wightman Stewart, which are used mainly for jobbing 2D cutting of metallic or non-metallic materials. The Psy-Winder 5-axis cutting headfitted to the WARDJet machines is a precision tool that is designed to cut bevels, undertake weld preparations and cut more complex shapes. It can be programmed to cut any three dimensional part between 0-90°. Its major advantage is the ability to cut a profile from a flat or angled piece of material at a pre-defined angle – anything between 0-90°. In addition, the cutting head can be programmed to cut a contoured profile, with the head remaining 90° to the material profile/surface. Image: GU Cutting & Grinding Services opted for WARDJet waterjet technology This is said to make the Psy-Winder ideal for the cutting of contoured surfaces, while offering all the facilities of 3-axis cutting, such as bevel cutting or providing an angle for weld preparation. Taper compensation of the cutting head results in increased geometric accuracy at faster cutting speeds. Dedicated software makes it fast and easy to program bevels on parts or to allow for taper compensation - virtually eliminating the taper commonly found on parts cut by a waterjet. Psy-Winder can create parts more quickly and accurately than with conventional waterjet and be used as an alternative to other forms profiling, such as CNC machining and wire erosion, it is suggested. The technology offers improved tolerances and geometries, while eliminating the need for secondary machining. Typical applications for Psy-Winder for GU are in the cutting of aerospace alloys, ceramics, glass and conventional metals. The WARDJet has abrasive and pure water capability, and is equipped with a drilling and tapping head for added versatility. Additional machining capability can be added at any time. "We are committed to giving our customers best value and the 5-axis WARDJet gives us a distinct competitive advantage," highlights Neil Kearns, managing director of GU Cutting & Grinding Services. "We have the capacity and capability to consider cutting anything with waterjet, and are happy to provide trial cutting and samples free of charge. The exciting element will be demonstrating the capabilities of waterjet cutting in not just metallic materials, but also wood, plastics, glass and many others." INVESTMENT IS A GAS Midtherm Laser is one of MSS Lasers (01788 552299) biggest users of nitrogen generation equipment. Located in Dudley in the West Midlands, Midtherm Laser has been in business since 2001 and has a diverse customer base, taking in the automotive, pharmaceutical, aerospace, petrochemical and architectural sectors. Parts produced by the company have been used in Bentley and Aston Martin cars, the Tate Gallery, Terminal 5 and for the 2012 Olympics. The firm is a Birmingham Post achievement business award winner, an Investor in People, and has ISO9001, ISO14001 and AS9100 accreditation. The subcontractor has three Bystronic lasers on its main site and a fourth laser located on a satellite site. "We started with bulk liquid nitrogen storage, so the costs were tank rental and the nitrogen itself," explains Dean Cockayne, operations director. "Other issues were the space occupied by the tank, which was located outside, and the logistics of delivery and reordering." When the nitrogen supplier relocated its call centre to Europe, the supply chain became unwieldy, leading to delivery delays, time wasted chasing deliveries and occasional disruption to the production schedule when the nitrogen tank ran out. "We could not tolerate this level of uncertainty and unnecessary administrative load, so we examined the possibility of nitrogen generation. We found that MSS Lasers was very knowledgeable, and had a fully tried and tested solution," Mr Cockayne reports. Midtherm Laser started by renting the system so that they could be confident that any breakdowns or teething problems would be resolved by the supplier. "MSS Lasers went into a lot of detail to ensure the system was properly sized for our current and future requirements. The service has been extremely good and we have now purchased the system with absolute confidence in its reliability and effectiveness," the operations director maintains. Image: Midtherm Laser's Dean Cockayne is more than happy with his nitrogen generating system, supplied by MSS Lasers The system installed comprises two nitrogen generators running in tandem, with a VSD variable speed compressor allowing the gas to be stored at 300 bar. All the equipment is now secure inside the factory and, because of the higher storage pressure, occupies less space than the old rented storage tank. "We cut at 20 bar, so we need 32 bar at the machine. The higher storage pressure allows us to store 33% more gas. Also, the tandem design of the system gives us a backup, in case of breakdown, as we can still run on one generator," explains Mr Cockayne. The company uses nitrogen to cut all its non-ferrous material, such as stainless steel, aluminium, copper and titanium. It is now also cutting thin gauge mild steel, up to 3 mm, with nitrogen, rather than using conventional oxygen. This allows the machines to cut profiles faster, while eliminating edge oxidisation, resulting in overall cost reductions, due to the removal of extra cleaning operations, which would have been required before painting or powder coating. Currently, Midtherm operates for 20 hours per day and the nitrogen generator easily keeps up with demand. Mr Cockayne concludes: "We have plenty of nitrogen, which makes it economical for us to use it on 99% of our products. Bought-in gas has doubled in price over the last 5-6 years, so we anticipate a payback on the system within two years. We can even tweak the purity levels of the generated gas to make it go further. "Our next investment will be in extra storage, as this will be the next limiting factor as we expand our production." TUBE CUTTING BENEFITS SJC Hutchinson Engineering has recently installed a BLM Adige LT8 tube laser (01525 402 555) enabling the Kilrea, Northern Ireland-based subcontractor to take on a broader spectrum of work, speed up the manufacturing process and keep costs down. "Investing in more productive equipment and in good people to run that equipment pays dividends in the long term," says Mark Hutchinson, managing director of the 55-employee, £6 million turnover operarion. "So, too, does our focus on quality of service – which gives customers the confidence that orders will be delivered on time and to a high standard of accuracy, and our emphasis on full traceability." With a round tube processing capacity of 12 to 220 mm and a maximum square section capacity of 200 by 200 mm, the LT8 Lasertube is capable of the intricate profiling of a wide range of tube and section weighing up to 35 kg/m. It has a 3.5 kW laser as standard and is fully programmable via the Siemens 840D Solution Line digital numerical control. The LT8 is available with an automatic bundle loader and an automatic single bar loader, as is the case at Hutchinson Engineering, or with two automatic tube bundle loaders. The latter option doubles to 5,000 kg the amount of material that can be held ready to cut. "With the LT8, we can provide customers with up to 40% savings, simply by eliminating multiple operations and the need for welding jigs," says Mr Hutchinson. "This gives us an important competitive edge, but our biggest challenge, in terms of moving forward, is making more people aware of the many benefits that result from using a tube laser." Image: BLM Adige laser tube cutting technology has benefited SJC Hutchinson Engineering Although happy with the performance of its two existing flat bed lasers and with a third now on order, Hutchinson Engineering opted for the LT8 Lasertube after seeing the technology in action in Italy. "With its 50-plus years of experience in tube processing, BLM Group has the right background, in terms of tube bending, cutting and profiling," Mr Hutchinson explains. "This is especially helpful when it comes to open profile and section (angle/channel) work. What BLM is not is a flat bed laser manufacturer that has decided to offer a tube laser machine. Back-up was an initial concern, but we have since enjoyed excellent service and support from the Group's UK operation." Box item Profiling news and products on the web [] Lantek, Kaltenbach and Remmert deliver innovative production solution for German company – Spain-headquartered CADCAM software specialist Lantek, sawing and structural steel working machine tool maker Kaltenbach (Germany) and warehouse automation firm Remmert (Germany) have worked together to deliver a production solution for engineering company Goldbeck, also of Germany – Details [] Economies of scale peg price of KMT Neoline waterjet pump – NextWaterjet cutting intensifier pump systems manufacturer KMT has put an entry-level price tag on its latest product, the 40 hp/3,800 bar Neoline – Details [] ESAB Data Leap software analyses cutting machine performance – Profiling machine supplier ESAB Cutting Systems has launched the Data Leap program, a production management software system that provides information on the performance of cutting machines. It can be used to improve machine performance, ensure production flows are optimised and be used as part of a fully automated manufacturing installation – Details [] Radan 2012 R1 sheet metal CADCAM promises enhanced tagging, nesting and bending – Advances in profiling, punching and bending, more control over the powerful nesting process – as well as greater flexibility using micro joints on profiling machines – are all promised by Radan 2012 R1 CADCAM – Details [] Water injection cutting and micro-nozzle technology make ESAB's M3 plasma unit more flexible – A water injection cutting capability for ESAB's M3 plasma system is designed to significantly reduce the cost of cutting stainless steel and aluminium, while improving edge quality and dross content – Details [] Techserv plasma tube cutter benefits from Baldor controller - An innovative new plasma cutting machine for flue pipes has been developed by Techserv Cutting Systems. Advanced interpolated motion of the cutting system is used to dramatically increase production throughput using an economic real-time machine control module from Baldor – Details [] West Midlands-based laser profiler Allfabs has taken delivery of a Mitsubishi ML3015LVP-45CF-R laser fitted with Mitsubishi Cross Flow Laser, supplied by World Machinery (with video)– Details First published in December, 2011