With the ConSus abrasive mixing unit, waterjet cutting specialist ConSus ANT is enabling the stationary use of water abrasive suspension (WAS) systems. A continuous suspension jet provides a more efficient cutting performance at lower pressure compared with conventional water abrasive injection systems (WAIS). For easy, customisable performance comparison of both methods, a free web app is available.

In many industries, R&D teams regularly develop new materials for which suitable machining processes must be found. For a large number of materials, waterjet cutting with WAS proves to be technically superior and economically more profitable than conventional cutting techniques. Compared with WAIS, the ConSus suspension jet operates at less than half the pressure and up to three times as fast. The user receives thin kerfs without hardening or material deformation. ConSus demonstrates its strengths particularly at increased cutting depths.

In contrast to three-phase WAIS systems with water, abrasive and air, the ConSus WAS system operates with a two-phase cutting jet of water and abrasive at a precisely adjustable flow rate. ConSus applies high pressure to the suspension before it reaches the remotely handled cutting nozzle. The high level of energy creates a cutting jet that emerges at almost twice the speed of sound. Its efficiency is much higher than that of the injection process, where turbulent mixing losses occur due to the contained air. The more focused WAS jet cuts precisely through even the hardest materials. That way, it is possible to cut material with a thickness of up to 1000 mm, while still maintaining very good surface structure.

ConSus operates at a maximum pressure of 1500 bar, even at enormous material thicknesses, which significantly reduces energy consumption and component wear.

For further information
https://waterjet-calculator.consus-gmbh.com

The precise processing of exceptionally large or thick plates is a job for specialists such as Otto Klostermann GmbH. Klostermann has many years’ experience and comprehensive know-how in processing large plates with its range of XXL-format machines. When it comes to thermal cutting – no matter whether oxy-fuel, plasma or laser – this plate processing specialist from Castrop-Rauxel uses modern, high-performance machines from Messer Cutting Systems.

With its newest investment, a LaserMat II, Klostermann now relies for laser cutting on the problem-solving skills of Messer Cutting Systems.

“Our old laser cutting system was getting on in years,” says managing director Philipp Klostermann. “It was no longer state-of-the-art and spare parts were unavailable. As the machine was totally loaded all year round, it was clear that we needed a new one. We are very satisfied with our existing OmniMat plasma and oxy-fuel cutting systems. They work flawlessly every day and have never let us down. An additional benefit is their size: we mainly process very large plates, and the Messer machines can process these XXL sizes. So, for us, only a laser system from Messer came into consideration.”

With the LaserMat II, the steel specialist found the perfect cutting system. The machine was conceived specially for large plate processing with its CO2 laser, and combines precision with speed – even when processing steel sheets weighing many tonnes.

With its new laser system, Klostermann can, for example, cut mild steel up to 25 mm thick, or stainless steel up to 20 mm thick. Thanks to the on-board laser beam source (resonator), it is possible to process plates up to 4500 mm wide and up to 30 m long.

For further information
https://uk.messer-cutting.com/

Trumpf has equipped its latest TruLaser Series 5000 laser cutting machines with intelligent assistance systems and a TruDisk 12001 disk laser offering 12 kW of laser power. As a result, TRUMPF says users can increase feed rates for medium-to-high sheet thicknesses by up to 50% compared with conventional 10 kW machines.

Higher feed rates mean higher throughput, with these new machines handling up to 20% more sheets an hour. The latest TruLaser Series 5000 machines come with tried-and-tested Trumpf features such as Active Speed Control and BrightLine Fiber, which lead to more reliable processes and higher-quality parts in both flame and fusion cutting.

Hendrik Meidert, product manager for the Trumpf TruLaser Series 5000, explains what makes these new machines so special: “Boosting feed rates by increasing laser power saves time in the cutting process, but that’s only part of the equation. For us, it’s equally important to ensure that we increase sheet throughput in order to improve the machine’s overall productivity. The key here is to reduce non-productive time or eliminate it altogether.”

It is not uncommon for problems to arise that slow down or stop the production process, especially when cutting thick mild steel. There are plenty of factors that might bring the cutting process to a halt, including dirty sheet surfaces, low-quality materials and variations in thickness between different sheets. These issues can lead to wasted time and materials.

“The higher the laser power and productivity of your machine, the more of an impact it will have when something goes wrong and your machine comes to a standstill. Intelligent assistance systems can prevent those problems from occurring,” says Meidert. “That’s why we offer functions designed to make dynamic cutting more reliable, especially for high-speed systems such as our TruLaser Series 5000 machines.”

For further information
www.trumpf.com

Ferro (Midlands) Ltd, which began operations in 2019, has used the success already enjoyed by the business to invest in pre-owned machine tools from Amada: an LCG-3015 3.5 kW laser cutter and HFE-1003 press brake. Both of these used machines, which were installed at Ferro’s Market Drayton facility and running within five weeks of first contact, have been fully refurbished by the Amada UK team of engineers.

Co-founder and company director Malcolm Evans, who has 18 years of industrial experience in engineering and supply services, sets out the reasons for investing in the machines: “We reached the point when our outsourced laser-cutting spend was on parity with the running costs of having our own laser and housing it in a newly constructed unit.”

Although Ferro initially considered low-cost options for its capital investments, including machines on eBay, the company was wary of the fact that it had not operated this type of kit previously.

“The idea of installing machines like these by ourselves, then working out how to program and use them soon became pretty daunting,” says Evans. “I know a few others who have gone down this road and most end up calling in the OEM’s engineers to sort things out. We decided we could get into a world of pain by not going through an authorised machine-tool subsidiary or dealership. We’d seen Amada machines at other companies and heard good reports, so they were our first choice.”

With its Amada LCG-3015 3.5 kW laser cutter, Ferro now provides a complete sheet-metal laser-cutting service for a range of materials, including steel, stainless steel and aluminium, from 1.2 to 12 mm thick.

For further information
www.amada.eu

Inside the compact footprint of the Winbro Delta laser machine is a spacious work area that offers X, Y and Z-axis travels of 1500, 750 and 1000 mm, supporting the continuous C-axis rotary table and ±140° B axis. Now, this next-generation technology is available from the Engineering Technology Group (ETG) after it became a technical partner of Winbro Technologies Group.

The latest Winbro Delta laser machining system can be applied to a multitude of applications that include percussion drilling, drilling on the fly, five-axis high-speed cutting, welding, 2D and 3D shaped-hole machining via ablation, ceramic coating removal via ablation, and aerospace cladding for repair or overhaul. The flexibility of the Winbro Delta laser machining system makes it possible to combine these processes in a single machine by using dual laser sources.

Inside the compact footprint of the Winbro Delta laser machine is a spacious work area that offers X, Y and Z-axis travels of 1500, 750 and 1000 mm, supporting the continuous C-axis rotary table and ±140° B axis. The Delta machine is capable of a linear and rotary accuracy of 0.015 mm and 15 arc/sec, with repeatability of 0.010 mm and 10 arc/sec.

Within the Delta platform is a raft of technology advancements, such as component scanning and mapping, focus control, a patented six-point probing system, breakthrough detection, crash protection, tool-tip interpolation, a quick-change nozzle system, and a selection of nozzle assemblies.
Winbro can integrate Delta with different types of YAG and CO2 Lasers and, in particular, a range of fibre lasers – the choice of which is dependent upon the application. Control is via a Heidenhain iTNC640 CNC.

For further information
www.engtechgroup.com