Why choose a steelworker?

The design of Morgan Rushworth hydraulic steelworkers is said to include many time-saving features which may not be apparent at first glance. As steelworkers have developed over time, a number of features have evolved to maximise the potential of these versatile machines.

These include optional flat-bar bending unit attachments. Many steelworkers see years of use for punching, shearing and cropping with the rectangular notch station barely being used. A more productive option for a number of users is to specify a new machine with an optional flat-bar bending attachment that can be mounted in place of the standard rectangular notch unit; these can also be retrofitted to many existing models.
Further developments of note include angle flange trim. Although many customers use the angle shearing station to crop angle iron to 45° to form a frame, not everyone is aware that for smaller sizes of angle, only one flange can be trimmed in the flat bar shear station. If one flange is sheared at 45°, utilising the notch provided in the flat-bar shear hold-down, then a frame can be manufactured with a ready-made weld prep on the outside of the angle.
Another feature worthy of mention is flat bar end bevelling. Using a different slot in the shear station hold-down, the ends of small flat bars can be offered up to the shear blades at an angle, allowing a partial shearing across the end of the bar, leaving a small bevel for a weld prep.
In addition, there are many different uses for a hydraulic steelworker, which can also be fitted with a multitude of special tools and attachments to suit special applications.
For further information www.morganrushworth.com

Tools feature magnetic safety system

Mate has expanded its press-brake tooling line with the introduction of American Precision Style tools featuring the new patent-pending Maglock magnetic safety system. Compatible with press-brake laser and optical safety systems, this full line of punches and dies is designed for press brakes configured with American-style holders and available in lengths from ½” to 18”.

Maglock uses rare-earth magnets to attach and seat the punch to the holder with no separation between the surfaces. The magnets are specifically and proportionally added along the punch shoulder so that the ‘up force’ of the magnet is localised and directed at the contact surface of the punch holder.
Safe and reliable, installation of a Maglock punch always results in the shoulder seating on to the holder, says Mate. The strong yet balanced Maglock connection is also said to simplify lateral (left or right) position adjustments. Once the punches are seated in the desired position, the holder clamping system must be engaged. Maglock does not claim to be and is not intended to be a replacement for the holder clamping system.
Unlike punches with mechanical designs (buttons, springs or pins) that become unsafe to use if the mechanism is damaged or missing, Maglock’s non-mechanical concept works safely all the time. Mate punches with Maglock offer additional safety if electrical, hydraulic or pneumatic power to the brake is cut off or damaged. In lengths over 4”, the design includes a lever to facilitate punch removal.
The reversible/symmetrical punch tang design enables the punch to be installed facing forward or backward.
For further information www.mate.com

Sharpe takes 7th Unison tube bender

Continuing investment in versatile all-electric tube bending machinery from UK-based Unison is boosting operations at tube and pipe fabrication specialist, Sharpe Products of Wisconsin, US. Sharpe recently invested in its 7th Unison tube bender to give the company an edge in meeting the ever-changing demands of the tube- and pipe-jobbing business.

Most customers no longer want to invest in stock, and batch sizes have reduced dramatically. These trends mean that machine set-up times become a major factor in job pricing. Any scrap generated during set-up – which can often run into several pieces when using older hydraulically-actuated bending machines – also negatively impacts job costs.
The first Unison machine bought by Sharpe Products was the Breeze 3” tube bender, and since that moment, the company has been a loyal Unison customer. Sharpe’s latest purchase is a Breeze 3” multi-stack, CNC-controlled, three-axis pipe-bending machine with a capacity of up to 3” or 80 mm diameter tubes. This machine has the ability to hold several tools for multi-radius parts or reduce tool changeover times, and is fitted with high torque servomotors to accommodate challenging materials. Also featured is a swing-away wiper-die servo axis to enable short, final straight part designs to be manufactured without post-bend trimming operations.
“Unison’s pipe benders are extremely reliable machines with innovative control technology and robust mechanical designs that help us to continually meet the demands of our customers,” says Paul Krickeberg, president at Sharpe Products. “On top of the great machines, they have great people providing great service and support. Unison offers the complete package.”
For further information www.unisonltd.com

Electric sheet lifters for press brakes

Gasparini has introduced its new press-brake electric sheet lifters, which are completely controlled by the CNC. The lifters are available in single- or dual-axis versions, with optional interpolation for better sheet tracking and support.

In dual interpolated axis configuration, the device continuously follows the part during bending, reducing the risk of scratches and counterbends. A counterbend can occur during the bending of very large, heavy or thin plate. The overhang generates a torque that makes the sheet bend around the die edge under its own weight. To overcome this issue, the sheet lifter supports the plate during the entire bending cycle.
An optional optimisation of the bending process consists of raising the ram before lowering the sheet lifter. This operation avoids, in case of a U-shaped bend, the return flange getting caught on the punch. When the ram goes up, the plate is lifted and then falls down, with potential damage to the part, tools and operators.
Sheet lifters are available in two sizes, providing a torque of 600 or 1200 Nm for the largest and heaviest sheets. Parts that needed two operators, can now be bent by just one person, in complete safety and without physical strain. In many cases, the use of forklfts and overhead travelling cranes may also be reduced.
Extended stroke allows bending angles as closed as 70° to be achieved. Height can be adjusted from -30 to +170 mm, to match dies with openings as wide as 100 to 160 mm. The resting surface is equipped with ball transfers and allows the installation of several options such as brushes, anti-scratch cladding, rulers, adjustable stops and telescopic extensions.
For further information www.gasparini.it

Why invest in custom press brake tooling?

According to Wilson Tool, deciding whether or not to invest in special tooling for a particular job is likely to give any fabricator food for thought.

While it’s true that custom press-brake tooling can be more expensive and may require a bit more lead-time than standard tooling, there are also significant benefits over standard tool sets. For instance, custom press-brake tooling makes it possible to solve challenging bending and forming applications while reducing material handling, minimising set-up time and improving the quality of parts.
Working with a tooling manufacturer to determine the best way to form a part can result in a positive ROI in terms of increased productivity and fewer reject parts. Whether faced with a unique part design, the need to simplify a complex bend or improve press brake performance, tooling manufacturers have the experience and knowledge to help shops determine the best way to make a part.
Tooling manufacturers also understand there is more to improving press brake performance than simply reducing the amount of time or number of strokes it takes to form a part. For example, consider the process of forming a channel. With a standard punch and die set, forming a channel requires two strokes of the machine. In contrast, using a custom channel tool, it is possible to produce two bends in one stroke. While certainly reducing the amount of time it takes to produce a part, the added benefit of choosing a channel tool set is the consistency gained in the finished component. As the part is now produced in a single stroke, it only needs to be gauged or located once rather than twice. After all, every time a component needs to be repositioned, re-gauged or relocated is an opportunity for something to go wrong, increasing the likelihood of producing a reject part.
For further information www.wilsontool.com