Posts Tagged ‘tooling’

A powerful 5.2kW laser cutting/profiling system, when fitted with an automatic load/unload system, can increase by up to 50% with typically only an extra machine investment of 20%

A leading supplier of sheet metal working equipment, Bystronic UK, will be exhibiting a wide range of equipment from its extensive portfolio of products at the forthcoming MACH 2008 exhibition. Among the exhibits will be five products previously unseen at an exhibition in the UK. Two of these were launched as recently as late 2007.

* CNC laser cutting and profiling – the Byspeed 3015 machine will be equipped with a powerful 5.2kW resonator and the all new ByTrans automatic load/unload system.

ByTrans has been specifically designed for those companies that produce predominately medium to large size batches with a limited selection of raw materials.

It is a portal system providing vibration-free handling of the cut sheets and the choice of model is dependent on individual requirements and space constraints.

Bystronic told manufacturingtalk.com that production can increase by up to 50% when a laser is equipped with ByTrans, for typically an extra machine investment of 20%.

* Compact design – the ByVention 3015 laser has a compact design, which makes it the smallest laser cutting machine for full-sized 3m x 1.5m sheets, claimed Bystronic.

The machine requires just 6m x 6m of floor space and therefore customers can utilise even the smallest of spaces.

The control cabinet and the system’s laser source are integrated in the machine frame and form a single unit.

Additionally, the cooling unit and the used air filter have been combined in a compact, powerful unit.

The ByVention is equipped with an innovative Bystronic designed materials flow concept, which makes all parts instantly available and ensures flexibility when using various sizes of material and partially used sheets.

Cut parts are continuously and automatically transported from the cutting area and are immediately available to the user even during the cutting process.

The removal area is fully accessible; therefore removal of cut parts is simple and convenient.

The machine is offered at a fixed price with the cost including the Bysoft CAD/CAM software package, commissioning and basic training as well as the two year warranty and preventive maintenance.

Thanks to the ‘everything included’ concept, the customer knows exactly what the investment cost is.

* Water jet cutting – the ByJet Pro, launched at the end of 2007, is Bystronic’s latest waterjet cutting system to meet the stringent demands in parts production without causing thermal effects in the material.

The machine is encapsulated for a cleaner and low-noise working environment and the new ergonomically designed shuttle table maximizes machine productivity.

The system on show will be equipped with four independently driven slim Z-axis cutting heads and this, when combined with the shuttle table concept, positioning/cutting speeds and axes dynamics, is said to be able to produce up to five times as many parts per unit time.

Additionally, the efficient programming software, Bysoft CAD/CAM, and the control and monitoring of the cutting processes by ByVision, ensure that non-productive time and material usage are kept to a minimum.

* press brakes (brake presses) – of two new press brakes to be shown, the Bystronic Beyeler Xpert press brake is said to deliver the highest repetition accuracy on the market.

This machine features an extensive and expandable database which is available at the touch of a button.

The control panel, with its intuitive user guidance, allows for ease of programming and operation.

Pressure reference (PR) bending technology, with hydraulic-dynamic crowning, continuous compensation of the side frame deflection, pressure control and protection of the tools against overload ensures maximum angle accuracy to satisfy the highest of bending demands.

In addition a Bystronic AFM EP 31-100 press brake with a bending length of 3150mm and a press capacity of 100 tonf (1000kN) will be on show.

The machine provides an economical and flexible press brake requiring minimal set-up and programming times.

With its 2D visualisation of the bending cycle and hydraulic crowning system the AFM EP range is the perfect introduction into CNC press braking.

* Software forum – there will also be a software forum where the range of Bystronic software will be demonstrated.

At previous exhibitions this has attracted great interest from visitors.

* CNC punch press – in addition to its own range of products, Bystronic UK is a supplier of the Pullmax range of punching machines.

The latest Pullmax 520 CNC punching machine, equipped with automatic load/unload facility for unmanned production will be on show.

The machine is capable of handling sheet sizes up to 2500 x 1250mm and has a tool capacity of 200 with a 20 station auto-indexing.

In addition there is the facility to press flanges up to 75mm.

Commenting on the company’s presence at MACH 2008 Bystronic UK’s managing director, Dave Larcombe, said: ‘This exhibition is going to be one of the most exciting for Bystronic and visitors to the stand with so many new products on show.

The message we are conveying is clear, Bystronic offers an optimal solution for every manufacturing application’.

He added: ‘We are in constant close contact with our customers.

With our very open approach and by listening to our customers, Bystronic is able to understand their requirements and produce and supply products to satisfy their needs’.

* Price deals on the MACH stand – where companies are having to come to terms with increased interest rates, Bystronic is addressing this issue by offering a number of fixed price deals and special price package deals to visitors to the stand.

Further details will be available on the stand.

Larcombe concluded: ‘This pricing system was introduced with the launch ByVention laser and has proved popular amongst customers.

The pricing includes delivery, assembly, start-up and training, software, maintenance contract and in the case of press brakes, standard tooling’.

Bystronic UK at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 4, Stand 4610.

Delcam, the software developer and distributor of such products as PowerMILL, Partmaker, FeatureCAM and ArtCAM, has a special hands-on approach to its software development process.

Delcam operates a machine shop, its Tooling Services Division, next to its software development headquarters in Birmingham, England.

The main aim of the facility is to allow comprehensive real-world testing of software before it is released to customers. However, it also operates as a working machine shop which is profitable in its own right. It uses the latest machining and inspection technology from manufacturers such as Mecof, Anyak, Matsuura, Bridgeport, Renishaw and POLI.

“The Tooling Services Division has always had a dual role within Delcam,” Brian Hawkshaw, division director, said.

“While we provide a real-world testing environment for our CAM software during its development, we are also required to operate as a profitable business in our own right.”

Delcam just added a WFL mill-turn machine with a three-meter working capacity to the Tooling Services Division.

“Until recently, we have concentrated on five-axis machining, both because that was the main focus for our PowerMILL development team and because five-axis operations increased our ability to take on more complex jobs and complete them more efficiently.

“The move into mill-turn has had similar motives. Delcam has expanded its product range with the acquisition of FeatureCAM and PartMaker, both of which offer millturn functionality, so we needed equipment with the ability to test new developments in these programs.

“Secondly, we have received more inquiries for large-scale projects that would only be possible to undertake efficiently with a mill-turn machine. We were taking orders for work even before we acquired the machine, and its capacity is already booked for most of this year,” Hawkshaw said.

He added that Delcam’s Tooling Services Division duplicated the diversification into other industries that Delcam accomplished with its software business in recent years.

“The aerospace sector now provides our biggest source of work, rather than the toolmaking industry,” he said.

Delcam sees the manufacturing expertise it gains in its Tooling Services Division as an important part of the comprehensive support it gives to its customers.

Besides helping the ocmpany’s development teams, experience it gains in the division is passed on to its support staff.

Hawkshaw said Delcam’s support staff uses the knowledge developed in the division to give its software users advice on all areas of their work, including the best choice of machining strategy and cutter selection.

Being able to test such developments on-site obviously gives Delcam a major advantage in proving out its software.

“Many CAM programs generate data that is mathematically correct but that is often impossible to machine in practice,” Hawkshaw said, adding that the company’s machine shop had a roll in the development of its PowerMILL software for high-speed machining and shop-floor programming and that he expects the mill-turn equipment to have a similar role in developing software for multi-function machining.”

JETCAM International s.a.r.l. today announced the forthcoming availability of the latest version V16 of its Expert CADCAM and nesting software for all CNC punching and profiling machines.

January 28, 2008 — The latest version V16, under the slogan of ‘Twice the power of V8’, includes a raft of new features aimed at providing enhanced functionality for interactive tasked and further automation for users looking for semi or completely unmanned solutions. JETCAM will also be increasing the number of end user releases in 2008, ensuring that customers can immediately take advantage of each new feature as soon as it is available.

JETCAM Expert V16’s sequencing routines have been optimised to further improve the cutting path which can considerably reduce the overall cutting time of complex nests. A new reporting engine has also been included to provide comprehensive and customisable reports. A report designer is included, where users can simply drag and drop the required fields or tables of information onto the page. Single component or complete nest images can also be added. Reports of any size or format can be generated, including labels for single label printers.

Further development specific to punching machines has also been announced. Automatic tooling placement logic has been further optimised, providing users of punching machines with the same level of automation as profiling machines. Tools are automatically placed on the component based on highly configurable parameters. This information is then carried through to all related nests – if the component is updated then this is automatically reflected on the nest. ‘Tool teach mode’ further enhances the automatic tooling facilities by allowing JETCAM to ‘learn’ a user’s preferred method of tooling a particular contour.

JETCAM’s free form high performance nesting module (FFHPN) for V16 has also undergone further development, with the latest release offering even greater efficiencies. With metal prices increasing even a 1% material saving can quickly mount up to a considerable amount. JETCAM is also offering prospective customers a free ‘nesting benchmark comparison’ whereby they will compare a user’s existing nests with one created through FFHPN.

Commented Mike Weber, Managing Director JETCAM International s.a.r.l.; “These features in Release V16, when combined allow a JETCAM Expert system to rapidly become self-sufficient. It intelligently and accurately applies logic so that the whole CAM process can become truly hands-off, especially when JETCAM’s Remote Control Processing (RCP) system is employed. With our knowledge of the complexities of today’s powerful CNC machines this frees the operator for other tasks, maximises machine runtime and reduces material waste. For any size of organisation this level of automation has to be their goal to remain competitive in today’s climate of cost reductions. Companies employing manufacturing efficiency methodologies such as ‘Six Sigma’ will benefit from a system that provides a data-driven approaches to problem solving with a focus on customer impact. Any business purchase has to be justified by return on investment, and JETCAM continues to deliver this in three key areas: material utilisation, machine cycle time and programming time.”

V16 will be available for download from the JETCAM.com web site in February 2008. Existing customers under maintenance will be able to download the software immediately at no cost. Customers out of maintenance need only to purchase a maintenance contract to gain access to the latest features – there is no additional upgrade price to pay.

For more information please contact Martin Bailey at Email Contact. Product box shots and company logos are available for immediate download from www.jetcam.com/logos.htm.

Contact information:

JETCAM International
Terrasses du Port
2 Avenue des Ligures
MC98000
Monaco

Tel : +44 870 760 6469

Web: www.jetcam.com

E-mail: Email Contact

Producer of low volume reaction injection moulded parts and polyurethane castings uses five vertical machining centres to cut master pattern equipment from polyurethane tooling board

The Midas Pattern Company specialises in the production of low volume, high quality reaction injection moulded (RIM) parts and polyurethane castings (PuR). The company intends to dramatically shorten the time and cost for a designer to move from a CAD model to a fully functioning prototype/finished usable component.

The production material has to validate design and produce a saleable product.

Midas uses five Haas CNC vertical machining centres (VMC) – typically to cut the master pattern equipment from polyurethane tooling board.

Midas said that one of the main reasons for choosing Haas CNC machine tools was reliability and user-friendliness.

Based in Bedfordshire, UK, the Midas Pattern Company was established in 1989 as a precision foundry toolmaking company.

The company has developed into a substantial business integrating CADCAM and CNC toolmaking techniques with traditional pattern and mould making skills.

Managing director of Midas, Alan Rance, said: ‘We aim to dramatically shorten the time and cost for a designer to move from a CAD model to a fully functioning example of a new product – not just a prototype, but a finished part, made from production material that not only validates design but is truly saleable in the market place’.

Midas uses a novel composite tooling system, MRIM, which offers a production moulding technique that can produce quantities from 1 to 5000-off.

Midas said it is ideally suited for making large parts or components with multiple assemblies and complex features.

Rance said: ‘We make parts in the production intent polymers that enable our customers to produce low volume examples of new and prototype products without incurring the very high cost of metal tooling or the compromises in functionality and mechanical properties you expect with traditional RP techniques’.

Based on RIM and PuR, the company’s FASTrim service offers a competitive alternative to SLLS/Silicon and VAC casting.

FASTrim can provide finished parts in as little as 10-15 working days, using cast PuR and soft tooling CNC machined directly from 3D CAD data.

Typical customers include medical technology companies building low-volume, high value instrumentation – machines that can cost hundreds of thousands of Pounds each but are usually built in low numbers.

* About RIM – Rachel Collier, Midas’ technical sales manager, said that reaction injection moulding, utilising MRIM tooling is ideal for the instrumentation industry.

She said: ‘Customers may only want to produce between, say, 10 and 20 finished products a year.

For example, if a customer designs and builds a new mass spectrometry machine costing many thousands of Pounds, it wouldn’t make sense to lay down metal tooling suitable for thousands of parts when you only need a few’.

Many of today’s medical equipment manufacturing companies are relatively small – often founded by individuals departing larger organisations – and perhaps only aiming at niche markets.

As recently as 20 years ago, such companies probably wouldn’t have existed without the patronage of a corporate benefactor – a large, well-financed parent organisation, for example – or some other significant investor.

Developing a new product was hugely and prohibitively expensive.

These days, even small firms can use the services of companies like Midas Pattern to get their products to market at a fraction of the traditional cost and to compete head-on with the big, well-funded players.

‘We’re not a typical plastics company so we’re not obsessed with high-volumes,’ said Collier.

‘We’ve taken all of the techniques and the principles we’ve learnt in the very specialised foundry pattern-making sector and applied them to making high quality plastic parts in small numbers’.

The Midas process starts by building tooling models within CAD (Computer Aided Design).

From these CAD models complex CAM (Computer Aided Machining) software is used to generate cutter paths.

The code for these paths can then be downloaded to one of the company’s five Haas CNC VMCs.

The VMCs include a 12,000 rev/min spindle VF-4SS, a VF-6 with a 4th axis Haas rotary table.

There is a a large 2m x 1m VF9.

The machines typically cut master pattern equipment from polyurethane tooling board.

‘Once we have the master pattern equipment we then use it to produce a composite metallised resin injection mould tool – MRIM,’ said Collier.

‘That’s about as much as I can tell you.

The detail of the process is a closely guarded secret’.

She added that the skill – the ‘Midas touch’, one could say – is being able to make a good quality tool from the master pattern.

Each of the company’s CAD engineers is also a machine setter, programmer and operator, so when it came to choosing a CNC machine tool, said Haas to manufacturingtalk.com, top of the list of essential criteria were reliability and user-friendliness.

Thanks in part to the precision of the master pattern equipment, Midas MRIM Tooling is guaranteed to produce up to 5000 parts, which is usually far more than a customer needs but does allow them to be used for intermediate production volumes.

A typical mould is around a 1m3 in size, which in the world of mainstream injection moulding would be considered extremely large.

Collier made the point: ‘If you made a hard tool for a part of that size it would cost around 10 times more than one of our composite moulds.

We can also achieve the complexity but without having expensive mechanical movements’.

* Pattern making – pattern making is a labour intensive process, so Midas still relies on its own knowledge workers – skilled pattern and toolmakers – as well as its state-of-the-art machines.

To keep them all busy, the company supplements its core business with a range of other activities.

The Bedford factory, spread across two adjacent sites, is essentially a tool making facility, which produces foundry patterns, jigs and fixtures, rotational mould tools, inspection fixtures and exhibition models.

It also houses a number of Low Pressure RIM moulding machines producing low-runs of finished parts.

‘What all Midas products have in common,’ concluded Collier, ‘Is that they all start with CNC machining, which means that every time Midas delivers a tool or a finished part odds are it started life on a Haas CNC machine tool’.

* About Haas Automation – Haas said that CNC machine tool companies have led the ‘democratisation’ (or freeing up – Ed) of manufacturing production, perhaps none more so than Haas Automation itself, which claimed to be the original low-cost, high-specification machine tool builder.

Founded just twenty years ago in California, USA, but already with more than 85,000 of its products in operation around the world, Haas said it has certainly played an important part in getting affordable, reliable tools in the hands of the ‘industrious and the ingenious’, helping companies like Midas Pattern Company to ‘turn bright ideas into gold’.