FEATURE ON BENDING & FORMING

Subcontractor upgrades press brake capacity

Bridport-based sheet metal subcontractor, Ackerman Engineering, has installed an Xpert 150-tonne, 3.1 m press brake from Bystronic.

The move adds to the six Bystronic models already on site, one of which dates back to 2001 and is badged Edwards Pearson, which the Swiss manufacturer acquired in 2002.
Managing director Graham Ackerman is particularly impressed with the latest Bystronic Xpert 150, for which he has bought a comprehensive suite of the manufacturer’s RF-A segmented tooling. He says it is twice as fast to set up compared with older style tooling, as the punch and die segments are automatically centred when loaded from the front and hydraulically clamped.
Moreover, the system is fully compatible with the Bystronic bending database in the machine control, and it is practically impossible to insert an incorrect tool due to laser beam recognition of its profile. Part quality is also improved, especially when bending long components, as there are no witness marks where the tool segments meet and there is no need for shimming.
Ackerman says: “Today we have 34 staff working at Bridport, including a fifth generation Ackerman, my son Edward. By the time he takes over the business, with our policy of constant reinvestment, we will have grown further. There is plenty of room for expansion on our current site. The purchase of highly productive production plant like the Bystronic machines will be key to our continued success.”
For further information www.bystronic.co.uk

Productivity leap for cam lobe manufacturers

Hatebur has developed and tailored its HOTmatic AMP 20N, a machine that is specifically designed for the manufacturing of forged cam lobes.

With this machine, the company aims to improve the efficiency and productivity of suppliers in the automotive industry.
“Almost all of the world’s forged cam lobes are produced on Hatebur machines,” states Thomas Christoffel, CEO of Hatebur. “With the development of the HOTmatic AMP 20N, we are reacting to new trends in the industry. We want to make our customers even more productive and strengthen our market leadership.
“The trend is heading towards thinner cam lobes in order to support the lightweight construction of engines,” he continues. “That is why the R&D division of Hatebur has started early with fundamental research on cam lobes featuring a thickness of 8 mm instead of 12 mm. The thinner cam lobes impose higher demands on the forming machine – in particular with regard to the shearing quality, pressing force and part transfer.
The HOTmatic AMP 20N offers a total press load of 1500 kN; the machine body has been reinforced to guarantee the necessary stability.
In three forming stations – and with a maximum of 200 strokes per minute – the AMP 20N produces cam lobes with an outer diameter of up to 48 mm out of raw parts with 24 to 217 g.
The up to 6 m long, almost 1200°C hot bars are brought exactly into position via four feeder rollers, powered by servo drives.
For further information www.hatebur.com

Boosting output with electric tube benders

Two all-electric tube-bending machines from Unison are helping Ultibend Industries to increase the manufacturing productivity of stainless steel tube fittings for food and beverage processing systems at its manufacturing facility in Wellington, New Zealand.

Ultibend purchased two customised tube-bending machines to suit its proprietary manufacturing process; the machines from Unison automate the bending of tube-fitting shapes such as elbows and U-bends, in sizes from 25 to 100 mm in diameter. Manufacturing operations have demonstrated that the Unison tube-bending machines have significantly boosted Ultibend’s manufacturing speed compared with its previous hydraulic bending machines.
“We knew of Unison as we have had dealings with them in the past,” says Ultibend director Linc Turley. “We like that being software engineers, Unison can take our ideas and issues, and come up with a tailored solution in the form of a customer-specific machine. They’re also an ethical company whose values align with our own. This has been proved in our dealings with them, and the excellent support and prompt response to any issues we have.”
Describing some of the key advantages of Unison’s machines, he adds: “The Unison solution has been invaluable as opposed to our old hydraulic system; the all-electric servo-driven machines give us greater control over bend parameters and increased accuracy. All the data is captured and automatically adjusted to the correct position during set up as opposed to manual adjustments. This gives us the ability to put lower skilled operators on these machines, as doing set ups and making adjustments is more straightforward.”
For further information www.unisonltd.com

Lean manufacturing events at Wilson

For over five years, Wilson Tool has offered free lean manufacturing training events to customers.

These events detail the company’s own journey and provide lean solutions that can be applied at customer facilities. The training is also a way for manufacturers to share ideas, success stories and learning experiences, while picking up tips from others.
Wilson’s lean seminars are a full-day event split into two different sections. The first focuses on basic principles like 5S, the seven deadly wastes and one-piece flow. Wilson’s training explores the underlying theories driving lean, coupled with experiments to apply them.
The second half of the day uncovers Wilson Tool’s lean journey and showcases product innovations that have come out of it. Participants go on a shop tour, taking a look at how the company has applied lean principles in the layout and flow of the plant. Representatives from the bending and punching divisions discuss tooling innovations that have helped customers streamline their own operations.
Ultimately, attendees will learn lean manufacturing principles that will help improve shop productivity and minimise excess cost and waste. Derived from the Toyota Production System or JiT production, lean manufacturing is a proven method for optimising output.
The next event is Wilson Tool’s LEAN 1.0, which is suitable for those with no lean training, or a basic understanding of lean principles. Set to take place on 20 September at the company’s headquarters in White Bear Lake, Minnesota, the training will run from 08:30 to 15:00.
For further information www.wilsontool.com

Forming on the modern punch press

According to Mate Tooling, forming on a modern punch press makes these machines the Swiss army knife of metal fabrication.

Today’s punch presses can mark, deburr and form. And when it comes to forming, there are opportunities aplenty.
Automated punch presses have been punching holes in sheet metal for more than 60 years.
However, with their stroke control and the availability of adjustable length punch holders, CNC punch presses are also being used as mini press brakes. Many types of forms are being produced in parts before they come off the turret or rail-type punch machine.
Countersinks and small embosses are among the basic forming tools being used in CNC punch-press machines to reduce or eliminate secondary operations. Lance and forms (tabs, bridges, knockouts, cable ties) and extrusions are among the advanced class of forms being produced on punching machines today. More complex forming tools include those that produce louvres, continuous embosses and hinges.
Forming tools add value by eliminating secondary operations such as forming, welding and installing fasteners. However, the press brake is not going anywhere. Space between the punch and die will always limit what can be formed on the punch press, at least for the foreseeable future, says Mate. However, if a part needs shallow forms like an embossment, a short flange or even a hinge, chances are those forms can be made right on the punch press machine bed, with no secondary operations required.
For further information www.mate.com