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Articles
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ProTechnique increases throughput with new EDMs |
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 by Jerry Cook
Installing two new Agie EDMs has provided ProTechnique EDM Inc., Milton, ON with a number of benefits including expanding the range of capabilities it offers as well as significantly increasing throughput.
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Brenco achieves improved efficiencies with new laser system |
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 by Jerry Cook
Installing a new laser cutting system has provided Delta, BC-based Brenco Industries Ltd. with a variety of benefits including additional production capacity and a significant improvement in laser cutting efficency for many parts.
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iMetal cuts into market with new laser |
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by Jerry Cook
No one has to explain to Danny Zoldos, general manager of iMetal Inc., Toronto, ON the importance of having inhouse laser cutting capabilities.
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New hiring trends in manufacturing |
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 by Thomas R. Cutler
Current trends suggest that Ontario will face a critical shortage of skilled metalworkers over the next decade.
According to a report by the Ontario Chamber of Commerce, more than half of the province’s skilled labor force is expected to retire within the next decade while there are too few qualified candidates to fill the void, which means Canada could be short one million workers by the year 2020.
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Tips for making accurate angle cuts in bandsaw operations |
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 There are a number of issues that must be considered to ensure making accurate angle cuts in bandsaw operations.
Most users making angle cuts are sawing mild steel tubing and structurals. Typically, problems encountered when sawing angles can be divided into four categories: the stock being cut, machine setup, the blade and cutting fluid, and the saw being used.
Initially, when an end user is experiencing problems achieving an angle cut that isn’t true, the first issue to be considered is the stock being cut. If it doesn’t meet mill specifications for straightness, there’s never going to be consistent angle cuts. Another problem that can cause inaccurate cutting is the conveyor that moves the stock into the saw. Make certain that it is securely fastened and is level with the saw table. Use one of the new laser beam tools or a minimum of a 6 ft. straight edge to insure alignment. The end user will always have problems making accurate angle cuts if the sawing machine and conveyor aren’t anchored to the floor and level.
Additionally, check to see that the stock is lying flat on the saw’s table and across the blade path. A loose machine vise has a tendency to lift the stock off the table; and worn pads on the gripping edge of the machine vise can prevent the stock from being held true.
The saw blade and cutting fluid are both critical components of any sawing operation. Initially, always inspect the blade prior to cutting. A damaged blade can cause many problems.
For instance, a blade with a broken tooth or one that is bent out of line from the tooth set can cause a jagged or out-of-square cut.
For making precise angle cuts, the widest blade a machine can handle should be used. Wide blades have fewer tendencies to wander, and they have greater beam strength so they won’t bend or deflect upwards when they cut. If the blade curves, the circumference is greater on the back of the blade than it is on the tooth side. The tooth side becomes wavy and doesn’t make straight cuts. Too heavy of a feed rate can also cause this problem.
When cutting tubing or other structurals, you are making an “interrupted cut”. That is the blade teeth start out cutting a solid then move to cutting “air”, then return to cutting a solid. This type of cut can be hard on teeth and it is important to select the proper blade pitch for these applications. It is tempting to specify a coarse pitch blade for making the solid portion of the cut; but too often, this leads to broken saw blade teeth and ragged cuts.
For the best results, have no less than three teeth in the cut at all times to distribute the load. Determining the proper blade pitch is based on the length of contact. For solids, this length is determined by measuring the diameter of a round or the side of a rectangle. For tubing, use two to three times the wall thickness. For structurals, use the contact length through most of the cut.
When cutting structurals and tubing use a blade with a wide set (the amount of offset the teeth have from the centerline is called set). A wide set cuts a bigger slot or kerf as the blade passes through the cut. Structurals and large tubing with thick wall cross sections have a tendency to close down or pinch as the blade passes through them. A wide set prevents the blade from being pinched and damaged. Cutting fluid dispersion is another area that can cause problems. If the fluid is blocked from being applied to one side of the cut or is significantly less on one side of the cut, the blade will have a tendency to dull prematurely. In other words, it will “walk” toward the sharp edge of the blade resulting in an uneven or out-of-square cut.
The end user should apply flood coolant through the saw blade guides when making angle cuts, particularly when cutting structurals or tubing. In this scenario, the interrupted nature of the cut can misdirect the fluid, leaving an insufficient amount of fluid in the cut. Flood coolant application assures the right amount of fluid reaches the cutting area. A lack of fluid can also cause chip welding where packed chips created by sawing can be heat welded to the blade gullets. Direct fluid application can also be used but it is usually only suitable for cutting one or two pieces at a time.
In some cases, angle cutting problems can be traced to bandsaw maintenance. Even though saw guides feature solid carbide inserts, the inserts eventually wear, break, or are improperly positioned so the blade rides too high and the tooth set is flattened. Roller bearings on the saw guides can also wear away; and sometimes the guides are positioned too far away from the cut so that the blade isn’t running true through the cut. The guide arms should be placed as close to the work piece as possible.
If the machine is properly anchored to the floor and conveyor, the stock meets mill specifications, and you are using the right saw blade and cutting fluid, there is little else to stop today’s bandsaw machines from making accurate angle cuts in all types of stock. However, the right saw must be used.
Bandsawing machines can be divided into three types. There are vertical or contour machines, which are suitable for making single cuts and are most often used for maintenance operations where accuracy isn’t critical. Angle cutting on these machines is accomplished by tilting the table of the saw or by using an angle cutting attachment
Tilt frame saws are vertical machines with a counter-balanced saw head that tilts to make angle cuts from 0° up to 60°. Some models have such features as a programmable head angle tilt with a digital read-out and automatic indexing with kerf compensation. They are used for production and general purpose sawing of large stock.
The most common bandsaws are scissor type models where the blade moves horizontally and the saw head is hinged on the saw base. Another type is supported between two columns and cuts like a guillotine. Both styles have models that are capable of angle cutting.
For smaller quantities, there are swivel head saws whose desired angle is manually adjusted and also NC controlled models that can be programmed for the number of cuts and lengths and are capable of multiple indexing. Some models have a head that can be rotated up to 45° in one direction and other more advanced machines have a double swivel head that can be rotated up to 45° in one direction and 60° in the other. Heavy-duty dual column saws with a guillotine type action are notable for their high accuracies and fast cutting rates for making angle cuts at production rates. Some operate by rotating the saw base and head around a fixed platform and can make angle cuts on work pieces up to 26-in. high by 22-in.
This article was written by Al Terronez, sawing and applications manager, DoALL Sawing Products, Elk Grove Village, IL.
doallsawing.com
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Lasertech diversifies services with Mazak laser system |
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 A recently installed Mazak laser cutting system has helped Lasertech Industries Inc. of Quebec, QC to diversify the services the firm offers and differentiate itself from competitors in the Quebec market.
“If you offer all the same services as your competitors, the only difference is price,” says Lasertech founder and president Denis Dubois.
With more than 25 years experience in sheetmetal fabrication, Dubois knew he had to offer his customers more diversified services when he started Lasertech.
“You have to offer new products and services to grow,” he says. “If you don’t grow, you’re going to die.”
Dubois started Lasertech five years ago with one Mazak 2D laser and a press brake in a 5,000 sq. ft. building.
Since those humble beginnings, he has upgraded his 2D capability to a Mazak Mark II.
Also during this same period, Lasertech has sustained an annual growth rate of 40%, built a 15,000 sq. ft. facility in Quebec, hired 30 employees, and bought a Mazak SpaceGear-U44. The company is ISO 9001-2000 certified.
“My SpaceGear-U44 is a tool to differentiate me to the customer, I can provide a service they can’t get from someone else.
“I’m trying to build long-term relationships with my customers for the 3D service – there are far too many 2D competitors to do that,” according to Dubois.
Continues Dubois, “We’re trying to bring something different to our customers.
“The services we offer like 2D laser cutting, welding, processing, and engineering assistance are important, but these things aren’t any different than what our competitors offer. The SG U44 is a complementary process that’s opening doors to new customers.”
Prior to purchasing the SG-U44, a triple-mode laser having 2D, 3D, 3D-tube and pipe with rotary capability, Dubois went through a benchmarking process, attended trade shows, toured showrooms, and spoke with business colleagues.
Dubois points out that Lasertech had been considering upgrading to 3D cutting capabilities for years.
“Every three to five years the equipment improves significantly,” he says. “If you don’t update, you are going to fall behind and lose.”
Through his evaluation process, Dubois determined that Mazak was number one in 3D laser customer support and that every Mazak owner he talked to was satisfied.
“I saw a growth opportunity in 3D laser technology when I first saw the SG-U44 at the International Manufacturing Technology Show and was sure it would help my company access markets that I couldn’t access before,” says Dubois.
Although he had no 3D work, Dubois was confident in his decision to pursue new markets.
“It really wasn’t that big of a risk for me-I had already started a business from scratch and proved that I could be profitable in two years. It was always part of my long-term strategic plan to grow by offering 3D laser cutting,” he explains.
Lasertech’s existing customers, however, didn’t share Dubois’ confidence in the new technology. “They didn’t see an immediate need, or thought it was too complex for what they were doing,” Dubois notes.
“3D laser work is so different than work on a 2D laser. With 2D cutting, you can install the machine and have it booked solid in two months if you are willing to compete on price alone.
“It takes time to educate customers on the capabilities of the SG-U44. There was also a learning curve on our part, as Mazak said there would be, and it took us some time to master it.”
Dubois singles out one part (shown below) that tested Lasertech’s new-found expertise in 3D laser cutting.
“It is a 3D aluminum prototype for a small sport vehicle,” Dubois says. (Itis) a formed part with special geometry, deeply drawn, with a lot of springback.
“We had to do a lot of advanced programming using the Mazak SPACE CAM software to get the part right, but we produced 50 prototypes in just 48 hours. The customer was very happy.”
Because Lasertech didn’t have the luxury of transferring many existing customer parts to SG-U44, all the work being run on it comes in as new business.
“We are doing things that we couldn’t do before and that’s why we bought it,” said Dubois.
“We have reached out to design engineers across the Eastern United States and Ontario to get parts from aircraft manufacturers, the automotive industry, and appliance manufacturers. “The SG-U44’s capabilities have opened new markets and that was the intent.”
mazakoptonics.com
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Southern Cross takes flight with Haas |
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 SURREY, BC- Many people in the Vancouver area feel that Southern Cross Machining is the leading small-parts fabricator in the lower mainland. Loyal clients rave (and even a few competitors concede) that it’s arguably the most respected job shop in British Columbia. Apparently, the reputation is well earned.
With a sharp eye on quality production, efficient workflow and smart machine utilization, this busy shop consistently turns out exacting, tight-tolerance work-on time and in spec.
For nearly two decades, an enviable parade of high-end customers seeking precision parts has relied on Southern Cross to deliver; and these very particular purchasers haven’t been disappointed. But surprisingly, in the last few years, the label “Most Demanding Customer” has been pinned on the shop owner himself.
In a number of interesting ways, this business is far from the ordinary. The name on the building-“Southern Cross” (borrowed from the Southern Hemisphere’s version of the Big Dipper)-should be the first giveaway of the shop’s heritage.
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