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DIGITALIZATION IS WITHIN REACH OF SMALL AND MEDIUM-SIZED COMPANIES IN THE SHEET METAL INDUSTRY

Change has become a constant in today’s world, and adapting will be essential in any sector, even in the sheet metal industry, where many small and medium-sized companies exist. The challenges these companies face every day are enormous. Equipping them with the right tools seems crucial if we want to move the sheet metal industry forward. 

One of these tools is digitalization. Having integrated systems that allow processes to be interconnected makes it possible to manage data quickly and efficiently, resulting in greater agility to adapt to the changes that occur at any given time. This seems easy, but it has been enormously complicated for these kinds of companies, which usually have limited resources to undertake this project.

A software ecosystem that breaks down barriers

There are indeed many solutions that have been born to help to digitize sheet metal cutting companies. However, the complete digitization of small and medium-sized companies, achieving a complete smart factory, is still an unfinished business in the sector. The bulk of the industry is still encountering obstacles along the way: high project costs, lack of personnel to manage tools that are complex in themselves, systems that do not meet the needs of the sector or company itself, and non-existent interconnection between the different software systems and business layers.

In short, solutions that should help a small workshop to be more agile and adaptable end up causing problems and headaches. And in the long run, users become reluctant to undertake new digitization projects because of the risk that this will be a burden rather than a benefit. That’s where systems like BySoft Suite from Bystronic come into play, a complete software ecosystem designed to digitize sheet metal companies and make the smart factory a reality for the industry.

Affordable and configurable software solution for every need

The new software solution launched by Bystronic has certain features that make it particularly suitable for small and medium-sized companies. The first feature that distinguishes this solution is its adaptability to the circumstances of each company. BySoft can be configured to adapt to any company’s digitalization status, size, and characteristics. This way, you can advance at the most appropriate pace in each case, depending on the objectives and available resources. This facilitates the path to digitization, especially for companies with a low digitization level. That can thus establish a medium to a long-term plan.

Another benefit is that it is an open ecosystem designed to interoperate with third-party machines and systems so that it can be integrated into all types of production environments. Many companies seek freedom by adopting software to integrate all their devices. BySoft Suite was developed with this vocation and can be combined with third-party systems and integrate operations outside the cutting and bending. The software connects the painting, drilling, welding, and other functions with the rest of the workshop devices so they can interoperate with each other.

Its hybrid character allows adapting the number of users at all times so that companies pay only for what they use and can adapt their costs to the needs at all times, in addition to avoiding costly initial investments. Cloud tools also make it possible to keep systems constantly up to date and enjoy all the functionalities added over time. This is a considerable advantage, especially interesting for small and medium-sized companies that, until now, saw digitization out of their reach due to the large number of resources required to undertake a process of these characteristics.

Making companies fit for the future

It is not about digitizing the industry for the sake of it. It is about helping to promote digitization that improves the prospects of a large group of companies that, until now, have not found a way to progress in digitization. It is about setting standards and helping to make the path easier so that all companies can be part of the industry’s future.

This will contribute to the sector’s progress and allow small and medium-sized companies to adapt to changes whenever needed, giving faster and more accurate responses to their customers, selecting the offers that best suit their business, or reducing delivery times. One of the great benefits of digitizing business processes is the ability to make decisions based on data, which helps generate certainty, fundamental in the current moment when changes are constant.

For more information on the please see www.bystronic.co.za or contact Bystronic on 010 410 0200.

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AMADA AUTOMATION SOLUTIONS

Ever-growing need for production has resulted in companies looking for unique methods of manufacturing with faster production times, less human intervention and ultimately less cost.

Labour costs play a huge role in production and the faster a product can be produced, the higher the profits.

In sheet metal applications, this is a difficult target due to the various stages of production such as blanking, bending, welding, grinding, painting, assembly, testing and packaging. These various processes are each a headache on their own.

Beginning with the blanking process, the designer needs to have a good understanding of the completed product and its intended use or application. This person also needs to have a good understanding of the capabilities of the machinery being used as well as the materials being processed.

The automation process begins by use of a CAD draw

ing system. Rendering a 3D model in Amada’s Sheetworks 3D software, the full product can be viewed, operated / animated and broken down into single part items. This process eliminates trial production and the waste of materials, time and resources.

Ultimately, all proto-typing can be done on a PC in the 3D environment, while the customer can sign off for the start of production before a single part or sample is physically produced. The process from creating the drawing to tool fitting and programming is executed by a few clicks on the PC mouse. The automated system will then separate material types and material thicknesses, it will nest the parts according to the parameters set and will program it accordingly for the selected machine.

Once completed at the programming stage, the programs are transferred from the PC to the machine by employment of a job card with a bar code attached. The use of a bar code scanner at the machine control will instantly display the program and rendering it immediately ready for production.

The scanning of the bar code will ensure that production throughput is handled in the correct sequence, thanks to the programmer who creates a production schedule according to the importance of the work. Once ready to begin with actual production, there is an additional automation option for material storage and material handling, too. These systems (ASF-H or ASR tower storage systems) & MPL (material manipulation system) are capable of loading the raw materials onto the table of the machine, ready for production to begin. All of this is possible without the operator having to touch the sheet. Once the sheet has been processed, it is offloaded by means of the manipulator system. It then is either stacked on a pallet complete with skeleton and parts or it can be separated by means of a “TK” system. The TK system is ideal for the removal and sorting of cut parts from a nested sheet. This “picker” will remove each individual part by means of numerous suckers and will place them onto different stacking pallets – sorting parts for their next processes needed onto individual pallets. Different customers’ jobs that were nested onto the same sheet can now be separated and stacked individually without any human intervention.  X3

Bending can also be automated according to customers’ needs by utilizing Amada’s 3i Bend software and creating all bending programs from the initial drawing. Sequencing and tool fitting is done on the PC and trial bending on the machine is eliminated. The “teach” function on the control of the bender will assist and indicate the precise positioning of each tool as required, while prompting the operator through the bending process. In the case of the ATC (Automatic Tool Changer), the machine will automatically load and unload tooling as required for the job at hand. The ATC will drastically reduce setup times between jobs as it can load a full three meters of top and bottom tooling in just 3 minutes. Suddenly the small batch runs or single part production becomes a much faster process with far less down-time.

For long constant production runs, robotics are available to replace operators. The robotic benders are ideal for constant bending of the same parts or very large production runs. These systems are available from very small robotic systems on the EG press brakes, right up to the large – heavy duty press brakes handling parts that are too heavy for the operator.

Amada provides a total automation solution for all requirements from single sheet manipulation (MPL), to multiple sheet storage and manipulation (ASFH or ASR) to high volume sheet storage and manipulation (MARS). Everything is programmed through a central Amada data-base (VPSS3i) and fully backed by Amada’s dedicated service and applications teams.

For more information, please contact Amada – Tel: 011 453-5459.

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TONGTAI CURATES SOLUTIONS FOR CUSTOMER PAIN POINTS

Easy monitoring of production information to manage production status at any time.

By Paul Savides, PBS Machine Tools

The current difficulties faced by manufacturing industries worldwide include a skills shortage caused by a slowing population growth rate, unhealthy dirty and dangerous working environments plus work-life balance initiatives and rising wages.

Circumstances that affect work performance have led the industry to gradually introduce automation to replace manpower. Corresponding to different production modes, unique situations need to be considered when introducing automation for any particular approach.

While in mass production, fixed products are produced over long hours, total accumulated load/unload time has a substantial impact on output. Time saving is of paramount importance and therefore, the introduction of suitable feeding units, such as robots is advisable.

If a production run involves variables, changing the line quickly is another important point to be considered. Additionally to equipment, project management and planning needs utmost focus.

Introduction of automation can bring a lot of benefits yet, sometimes after an investment, technical problems are found or maybe output is just not as good as what was expected. If the process is not perfect, any necessary modifications will force the production line to be stopped. Any defects found may be difficult to remedy if the system is complex or modifications may be extremely costly to integrate.

Therefore, Tongtai considers all possible problems from the very outset of planning, while identifying them by thorough analysis, evaluation, software and hardware integration and data management.

Hardware equipment to meet “Production Line Automation”

Tongtai supplies loading and unloading equipment, as well as peripheral devices used for testing, measuring and logistics which are most suitable for customers’ production line needs.

Multi-joint

 

Cartesian Coordinate
Horizontal Joint
Parallel

Software system to meet Information Automation

In response to historical production and management problems, Tongtai has developed a series of software programs that enhance the Human Machine Interface (HMI), including TIHMI and TIMS which make Tongtai machines intelligent, while vastly improving efficiency and TLM whole line management software which provides real-time data of production line status.

Data Management

Stand-Alone intelligent software (TIMS)
Whole-Line networking management software (TLM)

Management Tools to Satisfy “Management Automation”

Easy monitoring of production information to manage production status at any time.

The following is an example of a customized HMLV Tongtai manufacturing line:

This multi-variable production line can be reconfigured to quickly process any length of material, even bringing a single workpiece into the system, for immediate production before returning to a previous batch.

For more information please contact PBS Machine Tools – Tel: 011 914-3360.

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INTRODUCING INSERT TYPE MODULAR HEADS FOR MAXI-RUSH SHANKS

TaeguTec has recently introduced insert type modular heads for the MAXI-RUSH line of shanks.

The insert type modular heads of the TANG-SFEED, CHASE-MILL and NAN-RUSH products have been incorporated into the flexible MAXI-RUSH line in order to further diversify the popular line’s application range.

Due to their easy indexable head replacement of the shank mounted to the chuck, the additions to the line offer superior performance, improved productivity and reduced set-up time.

For more information please contact TaeguTec – Tel: 011 362 1500.

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INDEXABLE MAXI-RUSH SOLID CARBIDE HEADS FOR 5-AXIS PROFILING

Profiling with solid carbide ball type end mills on 5-axis machines has disadvantages, such as excessive machining time and poor surface finish. To solve these problems, TaeguTec introduced oval and lens shape solid carbide heads that are 3D profiling capable.

The new heads are designed for high-pitch, semi-finishing and finishing profiling parts used in the aerospace, power generation, medical and mould & die industries.

Even in high pitch conditions, the same surface finish can be obtained compared to solid carbide ball type end mills, and therefore the new heads are capable of high productivity machining.

 

Features include reduced machining time, increased productivity and similar surface finish even in higher pitch conditions compared to solid carbide ball type end mills, while in the same pitch and machining time conditions, solid carbide heads provide better surface finish over solid carbide ball type end mills. With the wider cutting edge contact improved machining stability and longer tool life is provided making it ideal for machining difficult-to-cut materials such as titanium alloy, Inconel and stainless steel.

For more information please contact TaeguTec – Tel: 011 362 1500.

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EXPANSION OF THE CHATTERFREE SOLID CARBIDE ENDMILLS LINE

ISCAR is expanding its range of EC-E7/H7-CF 7 flute endmills to include 3xD and 6xD length to diameter endmills. These are in addition to the already available 2xD and 4xD endmills.

The 7 flute, different helix and variable pitch solid carbide endmills have been developed for high speed / trochoidal milling and semi-finish and finishing operations. A unique patented design features a special tooth design to produce large chip gullets for efficient chip evacuation.

The optimal flutes and tooth geometries deliver maximum metal removal rates while maintaining high accuracy.

Made of IC902, an ultra-fine carbide grade, and TiAlN PVD coated for machining hardened steel, the endmills enable high productivity on most material types and an excellent surface finish even at maximum ap.  With low cutting forces and proven effectiveness in a wide range of machining speeds from 3,000 to 20,000 RPM, implementation of the new CHATTERFREE solid carbide endmills shortens cycle time and reduces tool cost while increasing productivity and process reliability.

When using an endmill that is longer than necessary, it is less rigid and requires reducing the cutting conditions. The new CHATTERFREE solid carbide endmills’ cutting length options and lower thermal impact reduce tool wear and provide an optimal tool for each machining requirement, enabling machining at the highest machining conditions even for difficult to cut materials. These endmills are small and cost-efficient tools, applicable also for low torque spindles.

For more information, please contact ISCAR South Africa (PTY) LTD – Tel: 011 997-2700.

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LOOKING FOR THE OPTIMUM TOOL

NEOITA, the ISCAR Tool Advisor expert system available for mobile phone use.

How can we define the manufacturer’s expectations from cutting tool producers? Cutting tool producers are expected to provide optimal cutting tool solutions for a given application. So, how is an optimal cutting tool defined for a specific application? It is obvious that standards must be set to achieve a formidable solution. Cutting tool standards are also defined by principles to enable choosing the best possible tool for a given application. Technical literature often states one tool or another as being optimal for an application. Therefore, a clear definition of the optimality standard is essential.

The criteria for finding the optimal cutting tool depends on various factors. The type of manufacturing (short-run, large-scale, mass), product range, machined materials, machinery used, cutting strategies and more have a direct impact on the manufacturer’s selection of the most effective tool. The manufacturer is interested in a tool that guarantees the highest performance levels. This can be achieved by optimizing the tool geometry and producing the tool from the most relevant cutting material grade. But the chosen geometry and grade are tool key elements associated with the type of machined material. So, what is the ideal tool for cutting? An example of an effective tool for machining cast iron, will most probably not be the best solution for machining heat-resistant superalloys.

Manufacturers are faced with constant dilemmas for machining vast choices of workpieces of different shapes and dimensions. The profile of a given application may dictate a long-reach tool, whereas in other cases the large overhang of the tool will have forced limitations that decrease machining stability which inevitably affects performance.

Selecting the optimal tool is one segment of many that relate to the core of the problem critical for all machining processes, which no doubt maximizes how to machine profitability. To reach this goal, various interdepended factors are considered such as the effective use of machine tools, competent process planning, available work-holding fixtures, and tool stock management among others. All factors are subject to optimization and finding the appropriate tool may prove to be an integral link to accomplishing the task.

Modern production abilities feature highly engineered CNC machine tools with advanced capabilities. New age premium machines are costly and reduce machining cycle time which in turn diminishes production costs. An ideal cutting tool should provide maximum productivity in combination with reasonable and stable tool life. To determine the appropriate solution, tool manufacturers develop advanced cutting geometries and new cutting material grades that enable reliable cutting at high metal removal rates (MRR) for diverse types of machining data. As the tool is expected to enable effective machining of different engineering materials, the geometry and the grades should be optimized accordingly.

Decreasing machine downtime is one more way to reduce production costs. The appropriate waymarks, which relate to tool attributes such as ensuring tool availability and minimizing setup time, can greatly contribute to the solution. Tool delivery is crucial for replacing “optimal” with “suitable”.

By saying, “the best tool is the one you have on hand”, one can understand important metalworking principles, making the ideal tool readily accessible.

In a perfect world, the ideal tool facilitates machining various workpiece shapes on long- or short-reach applications without loss of performance.  Tool customizing is an additional parameter for finding the optimum solution.

Advanced machines are expected to integrate optimal machining strategies. These strategies are planned, programmed, checked, and verified in a virtual environment of computer-assisted engineering (CAE) systems well before the process begins on a CNC machine. Therefore, the right tool should have an appropriate virtual component, a digital twin, to be embedded in CAE systems.

The wide array of ISCAR’s new products, introduced in the NEOLOGIQ campaign, is aimed at optimizing tool solutions for modern metal cutting. The NEOLOGIQ principles are conveyed by the use of new tool and insert geometries complemented by advanced grades. Among the many new developments, there are tools for Swiss-type lathes and multitasking machines.

Stainless steel and non-ferrous metals are common materials for manufacturing miniature parts in the medical and watch industries. Small and medium-size Swiss-type lathes are used for mass part production. A new generation of ISCAR’s ISO-standard rhombic turning inserts is specifically intended for this industry sector. A variety of precision ground and polished inserts enable productive machining with light cutting forces and significantly reduced friction.

Ground and polished ISO-standardized rhombic inserts intended for productive turning of small-size parts.

The cutting geometry is represented by two types of chipformers intended for semi-finishing, finishing, and roughing. The insert design with its many geometric attributes is focused on preventing built-up edge to ensure prolonged tool life.

ISCAR has developed two new carbide grades for milling different engineering materials effectively. IC716 is intended for machining titanium alloys. It is characterized by a tough cemented carbide substrate with high resistance to thermal cracks and a new high-hardness ceramic PVD coating with a smooth surface. IC5600 is designed for cutting steel. This grade features a submicron substrate, a multi-layer MT CVD coating, and an applied post-coating treatment. This combination substantially improves the resistance of IC5600 to abrasive wear and thermal loading and enables increasing cutting speeds and MRR.

The development of machine tools has made Y-axis turning methods common. These methods facilitate extremely stable cutting and enable the evacuation of long chips in a downward direction due to gravitational force. It is apparent that the metalworking industry increases its demands for advanced cutting tools specially designed for Y-axis turning. One of ISCAR’s prominent new product lines is the NEO-Y-SWISS line of integral turning tools.

NEO-Y-SWISS tools realize Y-axis turning strategy.

A modular tool concept that utilizes a tool assembly based on standard elements such as holders, heads, shanks, extensions, reducers, etc., is an effective way to find the optimal tool for specific applications. The distinctive feature of ISCAR’s new modular quick-change heads system NEOSWISS is comprised of diverse heads with indexable inserts for turning, grooving, parting, and threading operations on Swiss-type machines.

NEOSWISS, a modular quick-change head system for turning, grooving, parting, and threading applications.

This system enables removable heads and insert replacement in the limited working space of a CNC machine.

To stay up to date on modern age machining, ISCAR accentuates rotating tools with exchangeable cutting heads such as MULTI-MASTER and CHAM-IQ-DRILL. These modular lines with the “No Setup Time” phenomenon, enable quick head replacements that annul dimensional adjustment and CNC program corrections. This diminishes machine downtime and assures high machining repeatability. The modular design concept of ISCAR tool lines makes customizing tool configuration easy.

A significant functional improvement features ISCAR’s tool digital companion; 3D and 2D tool representations, tool assembly options, advanced E-Catalog and additional application software form the backbone of the virtual tool environment. ISCAR’s Tool Advisor, known as NEOITA, enables searching for an optimal tool for a specific machining operation. Based on engineering analysis and expert knowledge, this system generates a set of more efficient solutions with suitable cutting data, calculates MRR, cutting power, etc., and enables direct access to the e-Catalog, insert wear detection, and more.

A new responsive design application has brought NEOITA to handheld devices. Through cloud-based technology, the NEOITA is available 24/7 and in multiple languages.

NEOITA, the ISCAR Tool Advisor expert system available for mobile phone use.

For more information, please contact ISCAR South Africa (PTY) LTD – Tel: 011 997-2700.

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PFERD Abrasives – Innovative Solutions for Process Optimisation

PFERD is an industry leader in the development, production, support and distribution of premium tool solutions for work on surfaces including cutting, grinding, milling, polishing, cleaning and finishing.

As a major player in the abrasive industry within South Africa and on the African continent, PFERD is committed to continuous research and development to improve the quality, safety and ergonomics of its high-performance abrasives.

“PFERD tools produce less noise, vibration and emissions while requiring less effort to get the job done. Our innovative tool solutions enable businesses to optimise their processes and improve overall operational efficiency”, explains Dennis Phillips, National Sales Manager at PFERD-South Africa.

PFERDEFFICIENCY strives to deliver increased productivity and improved economic efficiency. It refers to the fact that PFERD products save energy by getting the job done quicker and decrease processing time due to their higher stock removal rates while generating significantly less waste—ultimately utilising resources sustainably.

“We continually improve our manufacturing facility and processes to ensure efficient utilisation of resources to sustainably produce the highest quality tool solutions that our customers depend on.

In addition, being a founder member of the Organisation for the Safety of Abrasives (osa), PFERD is committed to producing premium quality products that offer the user maximum efficiency, safety and comfort,” explains Phillips.

PFERD-SA, established in 1968, has five sales and distribution offices across SA and services the entire sub-Saharan Africa region.

An industry leader with a focus on training

The PFERDAcademy in Kempton Park offers free training to operators of abrasive equipment. “We believe the continuous training of operators enhances their performance and plays a direct role in the efficiency of the complete manufacturing process, explains Phillips”.

The PFERDAcademy’s grinding and cutting training addresses challenges such as operator fatigue, incorrect tool handling, material cross-contamination, consumable and machine incompatibility as well as non-adherence to labelled guidelines.

Phillips explains the aim is to correct operator behaviours that may result in injury, tool damage and loss of production time.

With over 9,000 products for surface preparation, finishing and cutting, PFERD offers a solution for various applications within a variety of industries and these innovations recently were on display at Electra Mining Africa’22.

 

“EMA is the premiere event to connect with customers – new and existing. Customers could see our high-performance tool solutions for themselves and the value it can add to their operations,” explains Phillips.

The PFERD Sales Managers and Technical Sales Advisors were available to discuss potential solutions to application problems as well as how the products can help improve operational efficiency.

Innovations such as the High-Speed Torus Cutter, a high-performance milling tool for stationary and robotic aluminium milling applications, were on display. And so was the CC-Grind Robust—a modern, high-performance and ergonomic alternative to conventional grinding wheels. It features high-performance, triangular-shaped, ceramic abrasive grain that achieves a very high stock removal rate while significantly reducing noise and vibration.

Phillips concludes, ‘’PFERD tools offer users maximum benefit and optimum cost-effectiveness. We are committed to premium quality products, while being a reliable supplier who operates with sustainability in mind”.

For further information, please contact PFERD – Tel: 011 230 4000

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VSHAPER 3D PRINTERS FROM B&R METROlOGY

In modern industry, we know how valuable it can be to have a machine that enables accurate prototyping, design freedom, small-lot production, and rapid tooling.

VSHAPER’s 3D printers have only recently arrived in South Africa but are used widely across Germany, the USA, and Poland. These printers are specifically designed for a variety of industries including foundry, automotive, aerospace, medical and education. As a result of its dedicated printer designs, VSHAPER can meet the varying needs of clients. Among their printers are the 270 series, 500 series, and the 5AX machine.

VSHAPER PRINTERS

The VSHAPER 270 series 3D printer is compact and designed to deliver fast, accurate results. VSHAPER’s smallest range is ideal for those looking to print smaller prototypes at an affordable price.

For more complex printing needs, VSHAPER’s 500 series is the best choice. The two-nozzle head of this 3D printer allows you to print two materials in one process – a main and support or two main materials, which opens up a wide range of possibilities when processing complicated models.

The 5AX is one of the most impressive printers from VSHAPER. You can forget about conventional printing methods with the 5-axis kinematics of this printer, equipped with a rotary-tilt work platform. It is possible to transfer the plane representing the basis for subsequent tool paths to another previously printed surface when using indexed 5-axis printing to strengthen the model structure in any direction within one object.

The use of 3D printing technology is well suited to prototyping, particularly when it is intended to present the product to potential investors and manufacturers. In today’s world, 3D printing technology for prototyping is often chosen instead of conventional techniques in order to save on time and cost. VSHAPER solutions guarantee efficient control of printing conditions and filament dynamics, allowing for 3D printing of individual elements of different sizes and complexity, forming a functional mechanism. This printing technology also allows for the creation of complex shapes with a degree of design freedom that is unavailable with traditional manufacturing methods. Thanks to its smooth production implementation, it gives a real alternative to small and middle-lot production and highly adjusted parts. This makes it perfect for prototyping.

In the era of precise 3D printers and a wide range of available materials, Rapid Tooling plays a vital role in dynamically developing companies. In order to shorten lead times and accelerate the test phase in production, companies can implement 3D printing technology in the production of moulds. Thanks to the heated chamber of the VSHAPER 3D printer, parts are produced with a smooth finish and minimal shrinkage. This makes it ideal for measuring and inspecting sample moulds, which becomes vital in producing the end product.

VSHAPER’s wide range of filaments is another reason they have become so popular in the manufacturing industry – from universal ASA and ABS to high-quality polyamide filaments, ending with high-temperature PEEK. The choice of using the correct material can have an immense influence on the quality, durability, and finish of a design. Their filaments enable and assure quality results.

When investing in a VSHAPER printer you’ll also have access to Softshaper, their cutting-edge 3D printing slicer software. This software uses the functionalities of CAD/CAM software in the 3D printing model preparation process.

For more information, please contact B&R Metrology – Tel: 011 663 2600

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SMART BENDING

By Gerrit Gerritsen, Product Manager Bending & Automation at Bystronic

Smart solutions to meet the demands of the market — this is what sheet metal processors require today. Good solutions are particularly in demand for bending. Machine manufacturers have many useful tools to increase efficiency and thus guarantee competitiveness.

From the smallest job shop to the biggest OEM, every manufacturer needs to get parts out faster, better, and more flexibly. Lean, just-in-time, on-demand, and Industry 4.0 are terms that have been used in this context. “Smart” could be the next key word.

Sheet metal fabricators need to employ intelligent methods that reduce costs and speed up production. At the same time, they need to be extremely flexible and efficient with raw materials and energy, including during the transport of material. In discussions with customers, machine manufacturers have noticed that sustainability and CO2 reduction are becoming more and more important. This calls for smart solutions and the use of smarter machines.

Smarter machines make better parts, eliminating any possible errors and reducing waste to the absolute minimum — all the way down to zero waste. Simultaneously, sheet metal fabricators need to make more parts within the same time frame, switching frequently between different programs. To enable this, a lot of intelligence needs to be integrated into the machine itself. But how can the goal of zero waste be achieved? How can speed be increased at the same time? What are the hurdles to be overcome?

We see three areas where smart solutions are needed:

  1. The part
  2. The operator
  3. The machine
ByCell Bend Smart Xact
ByCell Bend Smart Xpress

The part: BySoft7 is the smartest way to program

Today, sheet metal fabricators need reliable file formats in which they can store as much part information as possible, DXF is outdated and can handle hardly any part information. Bystronic, for example, uses STEP 242 files, which contain all the necessary data, including material information. This is important to ensure that calculations such as unfolded length and spring back are correct. Another problem in 3D files is the bend radius: In 99% of all bends, this is merely a vague number.

For a more precise flat pattern, the program recalculates the radius with distinct formulas based on empirical information. Similarly, it pre-calculates the spring back value. This solves radius, bend deduction, and spring back problems. But there is more: The perfect bend order has to be calculated, taking into account both part handling and precision. Bystronic’s BySoft7 does just that.

Xact Smart
PartID

Tools pose another challenge: Sheet metal fabricators need a program with information on the tools they actually own, where these are located, and if they are available.

As a smart solution, Bystronic’s Tool Optimizer works out the perfect production sequence for a number of parts. The program calculates the time it takes to change tools, the number of tools required, and the total weight an operator needs to move during a shift. In general, the set-up time and the tool weight to-be-moved can be reduced by 30%.

The last smart aspect of Bystronic’s software is that it can keep track of grain direction. It is well-known that changes in grain direction result in variations in bend results and different angles. Bystronic press brakes remember the direction in which a part was nested and can adapt the angle according to this direction.

Customers now have the best of both worlds. They can optimize their laser nests to reduce material waste. They can then also reduce part waste, thanks to the program knowing the direction of nesting and adapting angles accordingly.

The operator: Smart hidden help features

Operators need very clear information on required tasks. Most operators have limited experience with the huge variety of bending machines on the market. Machines and operators change at a faster pace than they did in the past. Bystronic helps operators by reducing text to an absolute minimum — after all; a picture is worth a thousand words. Any remaining text is displayed in the operator’s own language. Bystronic helps by providing clear instructions for where to put which tools.

The next step for operators using smart solutions can be taken with our camera-based Optical Tool Detection system. Cameras monitor the tools and tell operators everything they need to know. The system can even recalculate the complete program for an imperfect tool set-up. Finally, an automatic tool changer can be used for ultimate smart manufacturing. This prevents any potential errors. The operator calls up a program and the tool-changing robot quickly places the correct tools in their correct positions.

In addition, our sheet thickness measuring system helps operators when they need to work with varying sheet thicknesses. The machine automatically measures material thickness and compensates for any deviations from the programmed value.

It is also smart that Bystronic takes care of tools and machines. With smart sensors, Bystronic constantly check forces and verify measured values against the maximum admissible values in the machine parameters.

The machine: Smart deformation compensation

Machines deform during the bending process. Bystronic’s smart machine software compensate for all deformations: side frame deflection, crowning, temperature, and part position. This automatic compensation is done during bending, in real time and without the operator needing to intervene or correct. This is very important, as the smart compensation system makes Bystronic machines completely deformation neutral. The operator can bend any part on any machine — the results are always exactly the same.

As a result, all Bystronic bending machines are compatible with each other, and production can be swapped from one machine to another without any recalculation. The customer’s machine park therefore becomes very flexible. These are the benefits of smart solutions.

For more information on the please see www.bystronic.co.za or contact Bystronic on 010 410 0200.

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