Metal Forming & Fabricating

Material forming through stamping, notching, punching, bending, shearing, drawing and more using machinery such as mechanical presses, hydraulic presses, punch presses, turret punch presses, press brakes, shears, hydroforming machines, cold forming machines, hot forming machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

Hot Rolling Zirconium Pushes Possibilities

British engineering company Charles Thompson Ltd breaks ground with a scarce source possibly never seen before – a heat exchanger component rolled from an unusually thick (40 mm) flat plate.
Experts
Additive Manufacturing Systems

Human Powered Submarine Team Produces 3D-Printed Propeller

Testing of the 3D-printed propeller was successfully performed on the test stand at the University of Michigan’s Engineering Department. 
Take a look at how metrology and 3D printing distributor Burton Precision applies 3D printing technology to solve a variety of CAD issues and challenges for producing a unique plastic propeller design for a human powered submarine.
Automation/Robotics

Practical Success: Measurable Energy Savings in Die Casting Automation

More than 40 percent of the energy consumption takes place in standby operations outside the production process itself. In many cases, systems are not switched off in standby operations between production cycles and so they continue to consume energy.  
The integrated control system inside this standard casting cell with trim press from Reis Robotics saves the Pierburg foundry up to 30 percent on energy consumption.
CAD/CAM Software

Using Software To Better Run Your Shop

2D blanks for cutting and bending are produced from 3D designs by using the bending factors and punching tool data gathered from the punching and bending programming software. Numerous 3D interfaces also make it possible to unfold different 3D designs, including those received from customers or an engineering department. 
In today’s manufacturing environment, software has evolved. No longer designed for simple NC code and nesting parts for the best material utilization, it has become an increasingly useful and necessary tool for any production facility. Look for software modules which can be tailored to your needs and can create an ideal interaction between machine, control system, and production software. 
Coil Handling Equipment

Flat Metal Doesn’t Always Mean Stress Relieved Metal

Whether it's coming from a service center or an upstream process, most sheet or plate will contain residual stress, as shown in left sample, compared to same material (on right) after processing in a parts leveler.
Parts leveling can't free a shop from the stress caused by a missed shipping date, but it CAN relieve those production frustrations caused by metal components loaded with internal stresses that are released during welding, laser cutting, punching or bending. 
Laser Cutting Systems

Micromachining of Metals Cheaper, Faster with New Laser Technology

Figure 4. The precision and control possible using the fiber laser marker.
Advances in single mode fiber laser marking technology with superior beam quality can now replace traditional EDM or other micromachining equipment.
Plasma Cutting Systems

Heavy Fabrication Shapes Up to Meet Demand for Natural Gas

Chart uses its new heavy-duty plasma shape cutting machine to process a wide range of material thicknesses and sheet sizes ranging from 6 in x 6 in up to 10 ft wide x 40 ft long, cutting carbon steel up to 4 in thick, and processing aluminum and stainless steel in thicknesses up to 3 in.
Chart Energy & Chemicals installed an Avenger 3 plasma precision shape cutting machine from ESAB that added new beveling and marking capabilities and enabled the shop to slash its processing times, increase its capacity, and eliminate a second shift.
Press Brakes

A Focused Look at Specialized Tooling

With off-line programming, a programmer can verify can prove out complex parts before they run on the machine.
How do you find out if a specialized tooling solution is right for you?
Punch Presses

Why Shops Lean on Turret Punch Presses

The Q-5 punching machine can reach a bending height of 3.0 in on a variety of angles and even on parts which are nested in other locations than 0 deg to 45 deg and 90 deg, where its forming and bending capabilities turn the turret punch into a multifunctional part processing machine that can possibly eliminate a bending operation downstream.
Before investing in that next machine, take a moment to review some of these lean manufacturing aspects of the latest turret press technology to make sure you are getting the best value and strongest competitive advantage for your money.
Roll Forming

Roll Forming Opens Door to New Business

The Samco roll forming machine is custom designed to fit the parts being produced by Premier and maintain the tolerances required for the door framing headers and jambs in varying widths and heights.
Samco roll former allows Premier Products to offer improved door framing system, maintaining the tolerances required for door framing headers and jambs in varying widths and heights.
Sawing Systems

Sawing Systems

The RingSaw™ from Graebener-Reika is capable of cutting tubes, bars, and profiles with diameters ranging from 10 mm to 610 mm, and wall thickness from 1 mm to 150 mm. The machine is operated electro-mechanically without hydraulics, and is therefore oil free.  The cutting process is either dry, with a mini-coolant, or with flood emulsion.
A review of some of the latest technologies in sawing systems that can reduce your operating costs, improve your part quality, and increase your shop profitability.
Stamping Presses

Stamping Out a New Generation of Automobile Parts

To transport parts between forming stations, the press uses a modular transfer system that consists of autonomous units equipped with their own electronic drives to optimize the transfer motion for two forming stations at one time according to the particular part shape, and separately adjust the press speed and transfer motion so even difficult shapes with inclined forming positions in the die can be produced in continuous operation.(click on photo to enlarge it)
The question Ford and General Motors asked was how to produce hoods and doors with improved productivity, design flexibility and reduced costs. The answer from Schuler, Bosch Rexroth and Morrell was a compact crossbar transfer press that does all that and more.
Tube & Pipe Fabrication

The Secrets to a Long-Lasting ERP Implementation

The Tube Specialties shop in Tempe employs 97 employees in tube fabrication and assembly, including bending, end forming, machining, welding, brazing, swaging and non-destructive testing for tube assemblies. 
Infor VISUAL enables Tube Specialties, a fabricator of complex tube assemblies, to improve their overall productivity and shop efficiency, and support customer requests without spending excessive time and absorbing additional costs. 
Turret Presses

How Well Do You Know the Capabilities of Your Punch Machine?

New punching machine capabilities make it easy to manufacture a complete part with bends, forms, shear edge quality, all with a finish that is free of scratches, nibble marks or burrs, without any secondary operations.
Are you missing opportunities to produce parts profitably? Which of your parts currently require two or three machines to produce a completed piece? Let’s consider how you might put more profit in your pocket by producing those same parts with just your punching machine.
Waterjets

Specialty Precision Fabrication Shop Grows with Waterjets

Precision Waterjet Concepts uses a Jet Edge 4 ft x 4 ft High Rail Gantry system equipped with four abrasive jet cutting heads that is powered by a 150 hp waterjet intensifier pump.
Precision Waterjet Concepts uses waterjet cutting systems from Jet Edge to cut virtually any material, especially AR Plating and titanium.
Metal Forming & Fabricating: Products

Fully Automatic High-Speed Carbide Circular Saw

The P230B features a 750 mm diameter blade with a 3.8 mm blade thickness to minimize material loss. The blades can be either carbide tipped or ceramic (cermet).
The new P230B from Marvel Manufacturing is ideal for high production machine and features a 9 in maximum capacity on rounds and a 6.3 in maximum capacity on squares.

New Line of Ironworkers Increase Productivity

Workstations on each ironworker include either a 20 or 26 mm punch and matching die and standard punching tools, steel solid round and square bar shears, angle iron shears, flatbar shears and  rectangle notchers. Many special options are available, including V-notcher tooling, press brake, punching at notcher and more. 
Along with adjustable piston stroke distance, central lubrication systems, electrical back gauges, working lights and five individual workstations each machine, these seven new ironworkers from Marvel Manufacturing offer punching and shearing tonnage ranging from 50-192.

Advanced CAM Software for Waterjet Cutting

Intelli-CAM quickly generates multi-axis, machine-ready tool paths from complex 3D solid models. The software generates machine-ready cutting geometry through a few simple computer mouse clicks. 
Intelli-CAM from OMAX seamlessly generates tool paths from 3D models and further simplifies the cutting of complex, precision parts.
Events Calendar
September 8 - 13, 2014
McCormick Place -- Chicago, IL
September 10 - 11, 2014
Miller and Hobart Technology and Training Center -- Houston, TX
September 15 - 17, 2014
San Diego Convention Center -- San Deigo, CA
September 16 - 18, 2014
Houston, TX
September 17 - 18, 2014
John S. Knight Center -- Akron, OH