Celebrating its centenary in 2021, core business at Huddersfield-based Westin Drives centres on the provision of 24/7 service and repair facilities for electric motors and other electro-mechanical equipment. Until recently, any machining required was either subcontracted or limited to a single manual centre lathe.

Five years ago, the decision was made to bring machining in-house to address logistical issues surrounding the company’s low-volume subcontract requirement. With no prior internal machining knowledge, this facility has transformed to what is Westin Engineering today.
Westin Engineering has just taken delivery of its first five-axis machining centre, adding to two turning centres and a vertical machining centre equipped with a 4th-axis, all of which were provided by XYZ Machine Tools.
Initially, these machine investments were intended to support services at Westin Drives. However, the facility developed rapidly and, with strategic acquisitions, Westin Engineering has evolved into a full-service subcontract machinist offering everything from the reverse engineering of single components to volume production for a diverse
range of industries.
“Our primary priorities were milling and turning capabilities, which saw the arrival of the XYZ 1020 VMC with an optional fourth axis,” states Fraser Lynch, director at Westin Engineering. “This allowed us to machine larger bearing housings, while the XYZ SLX 425 ProTurn lathe was ideal for one-off and low-volume turning work to support Westin Drives.”
While these two machines enabled Westin Engineering to support its sister company, the next major move came in 2017 with the purchase of Kenward Engineering, a gear-cutting specialist, followed by the acquisition of general subcontractor, Kingsmith Engineering. These two developments brought with them a need for further machining investment.
“Much of the machining capability of these two businesses was either specialist gear-cutting equipment or dated turning and milling machines, so we needed to invest further, particularly in turning and milling capacity,” says Lynch. “We looked at mill-turn machines, but after speaking with XYZ Machine Tools we decided to acquire an XYZ CT65 LTY turning centre with LNS barfeed capability.
“With a Y axis and live tooling on our two CT65 LTYs it meant we could transfer a lot of work directly to them and reduce the number of operations required from four or five in some cases, down to just two operations maximum,” he continues. “The barfeed allows us to run unmanned throughout the night. During the day, the two machines are managed by a single operator, giving us significant efficiency gains for a vast majority of work. These two machines can achieve the work output of two lathes and two machining centres.”

With the bulk of the turning and milling now accounted for, attention turned to gear cutting. The acquisition of Kenward brought with it several specialist gear cutting, shaping and hobbing machines, but Westin Engineering was looking for greater versatility, especially for one-off or low-volume manufacture where the cost of specialist gear-cutting tooling was prohibitive. Smaller shaft and pinion work could be accommodated on the XYZ 1020 VMC, but larger diameter gears posed a problem. The solution was an XYZ UMC-5X simultaneous five-axis machining centre.
“We discussed our requirement with the applications team at XYZ Machine Tools and through their recommendation, we contacted Don Tyne Gear Systems, a specialist in gear design,” says Lynch. “Their software can generate gear data that can be transferred to our Open Mind CADCAM, allowing the machining of the full tooth form utilising the simultaneous five-axis capability of the XYZ UMC-5X.”
The combination of software and Siemens control on the UMC-5X makes gear design and manufacture almost conversational. By eliminating reliance on highly-skilled personnel, time-consuming calculations and expensive gear-cutting tooling, it meant Westin Engineering could provide a quick response and dramatically shorten lead times for this type of work. A further advantage is that by making use of sister tooling in the UMC-5X tool changer (with up to 60 positions), the machine can run lights out.
“Using standard probing and integrated ‘Smart Machining Technology’ on the UMC-5X we can monitor tool wear,” explains Lynch. “Alternatively we can set the machine to switch to sister tooling after a determined number of teeth have been cut, which ensures production is maintained overnight. All while using standard tooling such as ball-nose cutters.

“We see a lot of potential on the machining side and we’re identifying a lack of supply capability, especially where it involves more than just making to drawing and there is a requirement for engineering input,” he adds. “Our investment is enabling us to cut lead times on work such as this. Partnering with XYZ Machine Tools has additional benefits through their close working relationships with other suppliers, such as Open Mind and Ceratizit. In addition, the ProtoTRAK and Siemens controls bring added flexibility to our work. Throw in the cost benefit of the XYZ machines and it all makes perfect sense.”
This willingness to invest is paying dividends and has helped Westin Engineering to build on its reputation for delivering on its promises. Moreover, the company’s partnership with XYZ Machine Tools goes beyond the simple provision of machining capacity.
For further information www.xyzmachinetools.com

Significantly reduced machining operations leading to reduced part cycle times, improved operational efficiencies and new business wins are just some of the benefits that Baker Engineering is experiencing from its latest Doosan five-axis machining centre investment.

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, supplied Baker Engineering, a precision toolmaker and engineering subcontract specialist based in Derby, with the new Doosan DVF 5000. The machine was installed at the company’s new, purpose-built 8000 sq ft facility in April 2020, where it is being used to produce a diverse range of precision components, as well as specialist tooling, jigs and fixtures for its growing UK and international customer base.
Baker Engineering’s DVF 5000 is the second Doosan machine tool to arrive on site, the first being a new DNM 6700 vertical machining centre, which was acquired in February 2017.
Baker Engineering is a family-owned business established in 2008 that today employs 15 members of staff. The company is ISO9001-accredited and committed to continuous improvement, making regular investments in the latest machine tool and ancillary manufacturing technologies to maintain its competitiveness and strengthen its preferred partner relationships with customers.
A number of CNC machines can be found on site at Derby, including machining centres with integrated 4th-axis units, lathes with bar feeders, and wire EDM machines. In addition to offering precision subcontract machining services, the company has specific strengths in manufacturing aerospace component tooling (such as jigs and fixtures for ground support maintenance); tooling for the measurement and inspection of railway tracks; and tooling used in the power-generation sector.
As a forward-thinking company the decision to invest in the latest five-axis machining technology was a natural one, and had begun in earnest earlier in 2019.

Explains director Adrian Baker: “Multi-axis and multi-tasking machine tools help manufacturers improve their productivity. We’re a company that’s looking to constantly improve; we had done our homework into the technology and could see that an investment in a five-axis machine tool would deliver significant performance benefits. In addition, the investment would send the right signal, externally and internally, that Baker Engineering was focused on the future.”
The key advantages from investing in five-axis machine tool technology were immediately apparent to management and staff at the company and included: the ability to machine complex shapes/parts in a single set-up; the added benefit that ‘one-hit’ machining has on reducing the time and costs involved in set ups; and the ability to improve/maintain part accuracies owing to a reduction in work handling.
“Since the installation of the DVF 5000 we have experienced all of these benefits,” states Baker.
A demonstration of the machine’s capabilities, and its impact on Baker Engineering’s performance, can be seen when machining an electrical housing-type component. Prior to the arrival of the DVF 5000, this part was completed in five separate machining operations with a cycle time of 2.5 hours. However, when machined on the DVF 5000, the number of operations can be reduced to two, with a cycle time of 45 minutes.
“This is typical of the results we have been able to achieve since our investment in the machine,” says Baker.
Prior to making the purchase decision, Baker Engineering investigated the market in order to help identify the type of machine that would “fit the bill”.
“We were pleased with the DNM 6700 vertical machining centre that we bought in 2017 in terms of its performance and reliability, and have been impressed with Mills’ aftersales service and support,” says Baker. “When considering the five-axis machine investment it was natural that we approached them to discuss our requirements.”

The company’s discussions with Mills CNC led to the recommendation of the DVF 5000, which is a best-selling five-axis machine from Mills CNC’s machine-tool portfolio. This compact and rigidly-built machine is said to deliver high cutting performance and machining flexibility. The machine offers full simultaneous five-axis machining capability as well as 3+2 and 4+1 operations. Baker Engineering is predominantly using the machine for 3+2 and five-face machining.
Baker Engineering’s new DVF 5000 features a direct-drive spindle (up to 18.5kW/12,000rpm), linear guides and a 500 x 450 mm work table with 400 kg table load. The machine boasts 40 m/min rapids and was supplied to Baker Engineering with a 60-position ATC, integrated tool measurement and the latest Fanuc 0iMF control.
Since installation at the end of April, the DVF 5000 has been in constant use at Baker Engineering’s facility. As well as it helping the company increase its productivity and efficiency, the machine has also helped win new machining work.
“News travels fast,” states Baker. “On hearing that we had invested in Doosan five-axis machine-tool technology, a new customer made contact asking us to quote on a job. We have successfully turned that enquiry into an order.
“Our decision to invest in the Doosan DVF 5000 has been vindicated,” he concludes. “The machine has significantly strengthened our machining capacity and capabilities. It is fast, accurate and reliable, and represents great value.”
For further information www.millscnc.co.uk

The Nuclear AMRC (Advanced Manufacturing Research Centre) is part of the High Value Manufacturing Catapult alliance of seven research centres backed by Innovate UK. At its heart is an open-plan 5000 sq m workshop, containing over £35m worth of manufacturing equipment tailored for nuclear industry applications. Working with a range of challenging metals, including specialist steels and exotic alloys, the machine tools on site are protected by Vericut CNC simulation and optimisation software.

Andrew Wright, principal production engineer for the Machining Technology Group within the Nuclear AMRC, says: “Although we are the only Catapult centre focused on one sector, we also support wider UK industry with large-scale manufacturing challenges.”
One of the key drives for the centre is to take concepts that have passed TRL (Technology Readiness Level) 1 to 3, through and beyond the next phase of TRL 4 to 6 (sometimes called the ‘valley of death’). Generally, this requires a two-thirds scale demonstrator, proving the capability before the concepts go into full manufacture. And all the machine tools on the shop floor have been selected at a size that fits within this scope.
“We have some of the world’s biggest machining platforms available for R&D, taking workpieces up to 50 tonnes,” states Wright. “The Soraluce FX-12000 is one of the largest horizontal boring machines; it can accommodate workpieces up to 12 x 5 x 5 m, which is like two double-decker buses parked next to each other. With the ability to automatically change the cutting head to one of five different options, it is a very flexible manufacturing solution.
“Obviously there are a lot of other industries that use machines this size; we’ve produced large aerospace, oil and gas, and offshore wind turbine components,” he adds.
Other machines alongside the large Soraluce boring centre include: a HEC 1800 horizontal borer that can accept workpieces weighing up to 20 tonnes and measuring 3.3 m diameter by 2.5 m high; a Dörries VTL which can turn-mill parts up to 5 m diameter by 3 m high; a Heckert HEC 800 that provides heavy-duty machining in vertical or horizontal axes; and a large DMG Mori NT6600 multi-axis mill-turn machine.
These machine are representative of what may be typically deployed in the nuclear industry, but are often too expensive and important to remove from production to perform trials and tests. Instead, industry customers can access the capacity of the Nuclear AMRC without disrupting their own workflow.

Most of the machined parts produced at the Nuclear AMRC feature complex geometries, with limited clearance for cutting-tool access. In addition, the component could be a batch of one, so there is no margin for error. Protecting the machine tools has become second nature for engineers at the centre.
“With CADCAM programs generated in-house, all of the tool paths for our machine tools have to go through NC code simulation, and since we started back in 2012 we’ve worked with CGTech,” says Wright. “Vericut has been with us since the start and it’s vital that all our programs are proven in a virtual environment before being applied to the workshop.
“As you might expect with machine tools that are difficult and expensive to replace, we have detailed models and operational processes for each of them,” he adds. “With Vericut we can simulate to make sure there are no collisions between the machine’s structure, the component and the fixtures, and even the cutting tool, which could either gouge the raw material or be impinged trying to access any tight working spaces. For example, we recently completed a prototype part for a client on one our largest machines that had minimal clearance between its structure and the large component. Without an accurate digital twin of the machine tool, component and tooling, this would have been a very high-risk process.”
The Nuclear AMRC uses a variety of CAD packages, including EdgeCAM, SolidCAM and Siemens NX.
“The dedicated Vericut interface for each of the CADCAM software systems means we can run them side-by-side with uninterrupted data flow,” explains Wright. “Being a seamless integration, it allows the software to share our master tool and fixture databases.”
Vericut checks the actual G-code that the machine will run, so it provides the most accurate version of real-world events before they occur.
“Independent CNC simulation software like Vericut is vital; I could not image why any production engineer would not insist on using it,” he says. “We do not prove out any CNC code on the machine tools – everything goes through simulation. The only exception would be new capabilities not used previously. For example, CGTech recently added the facing-head option we have on the Soraluce machine. It’s a two-axis D’Andrea head that has CNC control to allow turning functions. Being able to control the cutting tool on a positioning slide enables features such as a sealing face or a taper on a flange face to be machined in situ.”
As well as equipment for decommissioning existing facilities, one of the growing areas of interest within the nuclear sector is that of small modular reactors (SMRs). An SMR is defined as a single reactor producing up to 300 MW, in comparison with current new build sites such as Hinkley Point, which has two units of 1.6 GW each.
The concept is to prove the design, manufacture approved standard parts in small batches rather than one-offs, and then factory-assemble the finished reactors instead of building on-site.
Says Wright: “Pretty much everything in a power station is a one-off. As it will be site-licensed for the particular location, it will have licences for its destination country and everything will be slightly different each time. The idea of the SMR is that, once proved, licensed and locked down, it will be exactly the same every time.”

The Nuclear AMRC team is always testing new machining techniques, to match both the geometrical requirements of the components and process needs of the industry, as well as addressing new material challenges, such as high entropy alloys.
“To fully support these areas we now use the Vericut Force module,” says Wright. “When looking at new and novel machining techniques, we want to know exactly what is going on. We input the Force data and take some measurements so we can plot out the results. It is ideal for tool life considerations; the nuclear industry is conscious of parts being damaged and tool wear is a factor. When we are looking at how to machine a component, the NC tool paths to be applied will be checked using the Force analysis module within Vericut to look for excess loading on the tools.
“It allows engineers to go back, tweak and alter settings for the machining, change cycles or even software packages. We’ve been known to use a completely different CADCAM package to get a suitable tool path. For rough machining, in particular, we are looking for a stable, efficient tool path. Here, we’ve found that the Force module is exceptionally good at narrowing down the best options. We’re also looking to see that we are not getting overloads; not going too deep or too wide on any cutting path.”
While most industry customers are looking to take time out of the manufacturing process, it is also about safety.
“What our partners and customers don’t want is any risk to high-value components caused by being at the cutting edge,” says Wright. “What we can do as a research centre using Vericut and Force is find out where that edge is and retreat slightly. Then we know it is a safe run up to these parameters and that consistent tool life will be achieved.
“The other thing we’re looking at on large machine tools is very dynamic tool paths, although we might actually end up breaching the limits of machine tools in terms of acceleration rates. If you have a dynamic optimised tool path from Vericut that is machining complex geometry, theoretically we can run at high feed rates using the latest cutting tools. The limit these days is not the cutting tool, it is other things in your process, and we can factor these into a virtual Vericut environment with Force to ensure the whole process is achievable, robust and reliable.”
For further information www.cgtech.co.uk

Somerset-based Watson Gym Equipment, a manufacturer of specialist strength training equipment used in high-end PT gyms, has recently invested in two new Doosan machine tools and a Doosan collaborative robot (cobot) from Mills CNC.

Watson Gym Equipment, created by owner and managing director Simon Watson in 1999, acquired its first Doosan machine, a large-capacity Puma 4100MB lathe, in March 2020.
This 15“ chuck, box-guideway Puma 4100MB is a rigidly designed and built machine suitable for a range of heavy-duty machining operations, including interrupted cutting. The Fanuc 0iT-controlled machine is equipped with a high-torque 30 kW/2000 rpm spindle, a servo-driven tool changer (12-position) and driven-tooling capability (7.5 kW/4000 rpm).
Since being installed, the lathe has been used to machine the company’s Pro Olympic weight plates, which are made from solid marine grade stainless steel. Weight plates are the flat discs located at either end of a weight bar to create a barbell or dumbbell used for weight training.
The acquisition of the Puma 4100MB lathe had an element of serendipity about it. In late 2019, Watson Gym Equipment had approached its existing CNC machine-tool supplier to discuss the best way to ramp up the production of its weight plates in order to meet increased demand.
Initial discussions centred on the acquisition of a new large-capacity vertical turning lathe to machine the components but, with an anticipated delivery time approximately six months after order placement, the company decided to consider alternatives and approached Mills CNC for help.
Says Watson: “We were aware of Mills CNC and knew that the company had a good reputation in the market for the technology it sold and aftersales services. We approached them to see if they could help with our specific machining capacity issue and, after an in-depth discussion, they recommended the Puma 4100MB. This large-capacity horizontal lathe was available from stock, and could be delivered and installed almost immediately.

“Mills took the time to understand our company and bought into our business model and what we were trying to achieve,” he continues. “They pointed out potential tooling interference issues that could occur by going down the vertical turning lathe route and, instead, demonstrated the productivity and flexibility benefits that we could expect to gain from investing in the Puma lathe. All of which, incidentally, have been correct.”
Watson weight plates can be supplied to customers in a range of standard sets (such as 150, 250, 350 and 500 kg) with individual plates weighing between 5 and 25 kg. All weight plates are machined to high accuracy and exacting surface finishes. Features include powder-coated end plates that can be customised (if required) with a customer’s logo or brand, and are supplied with a lifetime warranty.
“It’s relatively easy and cheap to manufacture weight plates from mild steel and add zinc- or nickel-plating to provide a professional looking finish,” says Watson. “However, after a short time, and through constant use, they will lose their lustre and the coating will peel, chip or discolour. Our business model is focused on manufacturing high-quality, high-performance and competitively priced premium products and equipment that look the part and which stand the test of time. That’s why we use stainless steel for our weight plates.”
Stainless steel is also used for the company’s range of best-selling dumbbell handles.
In early 2020, Watson Gym Equipment, with demand for its dumbbells at an all-time high, made the decision to increase its in-house production capacity and approached Mills CNC for guidance. Of particular concern was how to increase production of the company’s heavy-duty dumbbell handles, which are available in different lengths with a 30 mm grip.
“Dumbbell handles are not complex components,” states Watson. “They are machined from bar and cycle times are short. To meet increased customer demand we needed additional turning capacity, and we needed it fast. Having already established a good working relationship with Mills through the acquisition of the Puma 4100MB, we approached them again with our requirement and they recommended the purchase of a Doosan Lynx 2100LSYB lathe with a Hydrafeed bar feeder.”

The 8“ chuck/ 65 mm bar capacity Lynx 2100LSYB is a compact, multi-axis turning centre equipped with a high-torque main spindle (11 kW/4500 rpm), a sub-spindle (5.5 kW/6000 rpm), a Y axis (±52.5 mm) and driven tools (3.7 kW/6000 rpm).
Doosan’s Lynx 2100LSYB is suitable for small part production and is said to be fast, accurate and reliable. The machine and bar feeder were installed at Watson Gym Equipment’s facility in early May 2020 and its production capabilities have recently been increased further with the addition and integration of a Doosan M1013 cobot, which was delivered and installed later in the month.
The cobot, with its 10 kg payload and 1.3 m reach radius, is positioned in front of the Lynx lathe and programmed to unload the finished parts (dumbbell handles) once machining operations have been completed.
Says Watson: “The job and machining process were ideal for automation. We can set up the job and leave the machine running unattended overnight. As a consequence we have improved our productivity significantly and, as we’ve effectively removed the labour component from the process, have reduced the cost per part as well.”
Plans are well underway to increase the company’s floor space by an extra 22,000 sq ft with the building of a new machine shop adjacent to its existing facility in Frome. The new facility is expected to be completed by the end of 2020 and will house all the company’s CNC machining operations, including a new ‘Synergi 25’ automated manufacturing cell from Mills CNC.
The cell, which comprises a Puma 2600SY lathe (with Y-axis and sub-spindle capabilities), a 25 kg high-capacity industrial robot, an automated two-way drawer system (for stacking, storing and loading workpieces and finished components), a 17” touchscreen HMI, locating plates, pneumatic grippers and Sick safety systems, has been specified and ordered to help the company meet growing demand for its dumbbells.
“Automation is the key to higher productivity, operational efficiency and improved competitiveness,” says Watson. “The Synergi 25 cell will help us increase throughput and reduce bottlenecks, and exploit lights-out, unattended operations still further. We will be working with Mills CNC’s automation specialists in the next few weeks and months to create and prove out a bespoke manufacturing process at their Automation and Turnkey Centre in Leamington prior to it being delivered to our new facility.
“In the past six months we have developed a strong and positive working relationship with Mills CNC based on integrity and trust,” he concludes. “The technologies they are able to supply and the added-value consultancy they provide are helping us optimise our performance…making us fitter for the future.”
For further information www.millscnc.co.uk

Learning and understanding bending theory is probably as challenging as learning to be a good welder. It takes time and patience to learn the differences between every machine. Those differences can be significant, especially in a bending department with both old and new equipment. Marcel Fiedler, product manager – bending/automation at Bystronic Inc, reveals how technology has literally changed the way operators learn about bending.

Anyone starting a new job as a press brake operator before the smartphone era would spend most of his or her time going through the manual, guided by a veteran who knows the machine inside and out. The new operator would learn how to adjust the position of each axis, determine where the back-gauge needs to be, dial in the part, make other adjustments by typing nominal values into the controller, then run production until the batch ends. Once the basic concept of one machine is understood, the new operator would walk to the next press brake and learn this process from the beginning again, with the experienced tutor and manual alongside.
Programs would be created at the machine control. The material type and thickness are determined and the bend angle defined, before the back-gauges are positioned manually for each bend. If not provided on the blueprint, back-gauge positions would be specified as an actual absolute value that needs to be calculated manually.
Overall, 10 minutes (or longer) would be spent getting the press brake ready to make the first bend, and an old machine control would provide no indication of how this should be done. By looking at the control alone, the operator would not know which tools to pick or how to set them up. That is why an experienced operator is required alongside. He or she knows the set ups and best ways of doing it by memory.
At some point, new operators would be expected to work alone, so they would need a quick guide or ‘little black book’ close to the press brake to know which tools to pick.

Fast-forward to today. Imagine leaving the education system and looking for that first job in the sheet-metal industry. Thing is, new recruits today are not on the shop floor with an experienced employee who has operated just one machine for his or her entire career. Instead, they are in a classroom environment, sitting by a desktop PC installed with the press brake’s operating software. There is no printed machine manual to hand, and on some days there is no one with decades of press brake experience nearby, especially if they are needed on the floor. But that is not a problem, and here is why.
The controls come with a built-in guide to help operators understand each command. In actual fact, the operating system installed on modern press brakes is no different to any desktop PC. In this time of Industry 4.0, manufacturers are keeping pace with the latest versions of operating systems, like Microsoft Windows 10. The entire system is designed both for security and compatibility, with software that can communicate and connect with other equipment, office networks and the internet.
Software effectively ‘teaches’ operators to navigate through an interface of a product that is completely new. The HMI has no buttons or dials.
It is interesting how familiar that sounds. Smartphones have probably had the biggest impact on the way the industry interacts with machinery. There is no longer any need to push buttons or turn dials, and there is no need to take a blueprint, adjust each bending step, or define the X value of the back-gauge position. In fact, operators do not even see the X value being displayed on the controller; it is calculated in the background and corrected without any requirement for manual adjustment.
With offline programming, operators let the CAM software perform all functions as it takes the native 2D or 3D model and creates the program automatically. The software determines where to position each axis of the machine based on part geometry.

Industry has switched from a ‘passive’ HMI with function-specific buttons and dials to an ‘active’ touchscreen displaying a full 3D environment – a shift that mirrors smartphones and other technology used in modern-day life.
Back in the classroom, operators learn how to navigate through the entire machine control. Any adjustments made are simulated by the HMI, giving visual feedback. If the bend sequence or tool station positions are changed, the operator will see the HMI conduct a real-time check of any collisions that might occur.
A part with eight bends has 10,321,920 possible bend orders. That is 20 million possibilities for a collision before and after the bend. Today’s software checks all possibilities within seconds.
Operators now have full 3D visualisation of the part geometry, originating from the CADCAM software, which allows the CNC to calculate each axis position automatically. It is also possible to retrieve other relevant information from the control, such as which customer the parts are for and where the raw material is located.
So, how exactly do newer CNC press brakes create more parts than older mechanical or hydraulic press brakes? Well, the real time savings come during set up.
Operators do not need to bend part programs for years to know how to set up jobs properly. The control provides a guide through every step, displaying which tools are needed at which rotation (facing forward or backward) and, most importantly, where they should be placed on the machine bed.
For those forming a simple one-bend part, the length of the tool station usually does not matter, nor does whether it is offset a little to the left or right on the bed (though of course the punch and die need to be properly aligned vertically). Most jobs, however, require precise tool positioning, especially when bending boxes or complex geometries. Placing tools incorrectly means they could collide with a previously bent flange.
Ask any press brake operator if they have ever bent a part backwards and they are likely to say yes, and they probably were operating an older press brake when it happened. This mistake is understandable, especially when forming similar components or when bending two parts that mirror each other.
Controls with 3D graphics help prevent this error. Graphics show every contour of the part, including internal features, such as holes that can serve as a guide as the part is held in the press brake. When the part’s colour changes on the control screen, the component must be flipped ready for the next bend.
Enhanced HMIs and other technology advancements have not changed the bending fundamentals. No matter the age of a press brake, the radius during an air bend still forms
as a percentage of the die opening. Moreover, the forming process still elongates the material at the bend, hence the need for software to run those bend calculations. New press brakes also still use K-factors, bend allowances and bend deductions; they are just calculated automatically in the background.
That said, operators starting a career at a new press brake with a smartphone-like control will learn the job in a new way. Decades ago, operators would have learnt to visualise how a piece folded up. In contrast, when running a modern brake, a 3D simulation appears right in front of the operator.
In essence, the modern press brake HMI has changed how operators navigate their careers. The technology makes a talent search more flexible, guarantees more security in the production schedule, and makes a job in the press brake department an attractive offer for someone who is able to operate a smartphone. Even if a new recruit has never touched a press brake, he or she will be able to bend their first part after only five minutes, all thanks to a smart, user-friendly control interface.
For further information www.bystronic.co.uk