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NEWSLETTER Serving Pennsylvania, New Jersey, New York, Delaware, Maryland, and West Virginia
A Welmaintained tech prepping machine electricity for Fox’s Open House
Happy Spring!...almost. The team at Fox is growing impatient as we watch the tulip buds get covered by Nor’easter after Nor’easter. Similar to our customers, we grow tired of weather delays and slow travel; and have turned our focus to opening the office windows and doors. That includes the doors of our new showroom where machines are rolling in for our Open House in May. Accurpress, Mazak, SafanDarley, Davi and Hyd-Mech are a few of the highly respected manufacturers participating in what will be an eye-opening and educational event. Preparing for the latest technology to arrive - our team
expanded the dock doors by four feet, brought in new showroom flooring and installed a new HVAC system. A few guests among many include Bob Macaulay from DocLogic for educational sessions in press brake forming; as well as Al Bohlen from Mazak who will be breaking down the fine details between DDL, Fiber and CO2 technology. Brandon Kiffer of RADAN is offering demos with their CAD-CAM sheet metal cutting software solutions. Dave Goose of Manufacturers Capital will be joining us to discuss the newest tax laws and their impact on equipment financing. On-site credit approval will be available to anyone interested. We are looking forward to hosting our customers May 22nd through 24th and hope you will join us. For full event details, visit our website: foxmachinery.com/open-house/
Inn This his Issue ssue
The Acceleration Effect - Waterjet Cycle Time......page 1 What is DDL Technology?......page 2 Preventative Maintenance: Shear......page 3 Open House Info......page 4 Listing of Used Machinery......page 5 25 Types of Metal Forming Knowledge Test.....page 6
FoxMachinery.com
2018 version now available in web-reader format
The
Acceleration
Learn why rapid acceleration/ deceleration in WATERJETS is necessary to lower part cycle time.
Effect
Article contributor: Flow Waterjet
In October of 1997, Andy Green drove his Thrust SSC car on a one-mile track in the Black Rock Desert to set the current official world land-speed record of 763 miles per hour. In June of 2017, Lewis Hamilton reached a top speed of 197 miles per hour in winning the Canadian Grand Prix Formula One World Championship in Montreal. Using simple math, you might conclude that Green and his Thrust SSC could have easily won in Montreal since he reached a top speed almost four times as fast as Hamilton, right? Obviously, it’s not that simple. Where Green had a short, straight line track, Hamilton had to negotiate a dozen turns each of his 70 trips around the circuit. You may be wondering: but what does it have to do with waterjet cutting? EVERYTHING.
For years, waterjet manufacturers have been using raw cutting speed defined in inches cut per minute as a measure to compare different machines. Traditionally, a waterjet that cuts 700 inches per minute was considered superior to one that cut 500 inches per minute. But there’s rarely been a mention about how long it takes to get to that top speed. In real world applications, most shops rarely have the need to cut 700 inches in a straight line – like Andy Green’s straight-ahead track. Most waterjet machines need to cut shapes ...continued on page 2...
March 2018
WHAT IS
Direct Diode Laser
Better than fiber, DDL Lasers are: 1. More Efficient 2. Faster 3. Better Quality Cuts
TECHNOLOGY?
The Buzz about DDL Article written by Al Bohlen, President Mazak Optonics Corp.
Recently, Mazak Optonics Corp. introduced a first of its kind laser-cutting machine which utilized a direct diode laser (DDL), the Versatile Compact Laser - Tube 100 (VCL-T100). Now we have announced another direct diode laser, the OPTIPLEX 3015 DDL. This machine has changed the game for high power laser cutting. Direct diode laser technology has shaken the industrial lasercutting industry, but not everyone understands what it is, how it works or why it has gained such traction.
What is Direct Diode Laser (DDL) Technology? The name explains the process. DDL technology utilizes diodes
...CONTINUED FROM PAGE 2... which require constant starting and stopping to navigate multiple curves and corners -– like Hamilton in his Grand Prix race.” Excerpt from Flow Waterjet’s free e-book “Acceleration”. Download the full e-book HERE.
Conversations surrounding waterjet performance in repeatability, pressure, and velocity are influential factors to determine if a waterjet is a smart investment. Traditionally, manufacturers value waterjet technology for its versatility, along with: • Lack of heat generated during manufacturing • Does not produce harmful dust or particles • Narrow kerf width • Does not leave a burr or a rough edge Many of us have been amused by videos of waterjets demonstrating cutting power on a straight line – cutting anvils, angle grinders, and bowling balls are a few examples. For manufacturers, power and speed on a straight line does not necessarily demonstrate the machine’s ability to perform effectively in their workflow.
#1
directly. This is managed through eliminating the doped fiber system used in fiber laser technology. Which in turn, makes the DDL course more efficient since the middle process is now eliminated. Direct diode lasers are also the smallest and most reliable laser source, all while having an exceptionally high quality beam.
Why is DDL now being introduced as a laser source?
Until recently, DDL has only been available in lower power levels less than 2,000 watts, which has limited its use in a wider range of industrial cutting applications.
In the e-book, Flow explains that waterjet manufacturers convert the “0 to 60mph” analogy used with cars to a measurement of gravity, or g-rating, for waterjets. A consumer will find waterjets ranging from 0.01g to 0.05g, the lower rating being the higher performer. Understanding how manufacturers refer to speed versus acceleration helps to predict how a waterjet would perform as a part of your workflow. Speed refers to the distance the waterjet’s cutting head is traveling over a period of time. Acceleration is the time which it takes the cutting head to reach its given speed. While machine speed is a variable not to be discounted, if we look at our two samples on a waterjet cutting at 700 inches per minute, consider the distance available for the machine to reach full speed. Looking at the size of the cutting head, sample #1 may allow for one inch of space to accelerate and decelerate before making a tight turn. Because the arc in sample #2 has a larger radius, the machine is able to maintain a higher speed. This information can be used to estimate processing time as well as the efficiency of waterjet technology for your manufacturing needs. With the goal of achieving a “low cost/high quality/fast production” ratio, understanding how a waterjet approaches a job allows for a better estimate in shop value. To read more on the acceleration factor in waterjet technology, click the image below to read the full e-book from Flow Waterjet.
#2
samples from a waterjet comparing the number of turns needed to complete the part and the surface space available before and after the turn
To cut parts similar to those pictured above, Flow recommends manufacturers give attention to a machine’s acceleration and deceleration capability. When comparing the cutting head to a race car, precise turns involve deceleration before the turn in order to control momentum through a change of direction. Looking at the samples above, the need to reduce speed to make intricate turns is far greater in #1 than in #2.
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CLICK THE IMAGE ABOVE TO DOWNLOAD FLOW’S FREE E-BOOK ON WATERJET ACCELERATION.
610.275.4700
Today the platform has been developed and expanded to accommodate 8,000+ watts of power. These higher power levels combined with its very unique characteristics including reliability, efficiency and quality have now allowed DDL to be utilized in thicker material applications. While many laser users have embraced solid state laser technology and the benefits from higher cut speeds and lower costs of operation, these users have desired high edge quality that has not yet been possible with fiber and disc technology.
PREVENTATIVE MAINTENANCE:
Shear
Keeping a consistent eye on your machine is the easiest way to minimize downtime and maximize productivity. Manufacturers often recommend conducting preventative maintenance on shears by interval hours. Below is a general outline. Fox Machinery and Welmaintained encourage our customers to use this as a starting point to develop a plan based on your machine’s usage.
Every 100 Hrs Every 9500 Hrs Clean backgauge guideway Lubricate main motor Lubricate lead screw Check motor overloads Adjust acme nut for backlash, if needed Inspect control console Check ball transfers
What are the benefits of DDL?
There are three key areas which DDL has made advancements over CO2, fiber and disc laser technology.
1. First is the overall efficiency of the laser.
As you can see from below, Mazak's DDL has improved wall plug efficiency compared to any of the other laser sources. This is because the diodes can be used directly instead of having to go through the doped fiber system. 2. The second key benefit of DDL technology is the cut speeds. DDL has cut speed advantages typically about 15% faster in all material types and thickness, but it is most notable in aluminum. We are seeing, in come cases, 30% faster cut speeds in aluminum over fiber or disc. 3. However, what is most notable is the superior cut quality in all materials over the typical results seen in fiber or disc technology. Due to the DDL wavelength and beam shape characteristics are different than the other laser sources. The DDL characteristics are such that we can provide a more superior edge quality not yet seen on fiber or disc laser all while running at speeds, which in many cases, are faster. DDL have the ability to cut a wide range of material types and thickness, which certainly include a variety of steel compositions, aluminum, stainless steel, etc.
Annually Change hydraulic oil Replace the return line filter Check for user & maintenance manuals Check suction strainer Check limit switches Clean the lenses on light curtain Re-torque key bolts Check relief valve Inspect all wiring Check valves Inspect safety decals Inspect safety guards
Every 400 Hrs Check hydraulic oil level Check shadow light bulbs Rear bearing greasing Blade gap adjustments Lubricate link bearings Check lead screw endplay Check backgauge bar height Check drive gear belt tension Check flip-up arms Calibrate backgauge Every 500 Hrs Check ram thrust bearings Check squaring arm Check bolt tightness Inspect blades
Every 1000 Hrs Check fill cap Adjust shadow line Inspect backgauge drive belts (or chains) Check backstop bar parallelism Check for leaks Check for loose fittings Check cooling fan Check heat exchanger
New Machine 2 weeks in use : Blade gap adjustments 6 months in use: Re-torque the key bolts New Blades 2 weeks in use : Blade gap adjustments
DOWNLOAD THIS LIST TO SHARE WITH YOUR MAINTENANCE TEAM
CONTINUED ON PAGE 4....
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Fox Machinery 2018 Open House Tuesday, May 22nd - Thursday. May 24th 9am to 4pm at FMA’s new showroom: 313 National Road, Exton, PA
Join us for three days of educational seminars, live demos and new technology geared toward:
Business Owners, Managers, Fabricators & Operators
Mazak 6kW Nexus Laser Hyd-Mech S23A Saw Timesavers 37″ Rotary Brush Safan Darley E-Brake Accurpress Accell E Press Brake Davi Angle Roll & 1/2 x10
• “Compare & Contrast: DDL vs. Fiber vs. CO2” Seminar • Brainstorm session with your Sales Engineer • Demo state of the art technology in our NEW 10,000 square foot building • Press Brake Forming Seminars with Bob Macaulay from DocLogic • Network with like-minded business owners, managers, and fabricators • Shop for tooling and used machines • Practical solutions to increase productivity, improve efficiency and eliminate unnecessary expenses • Understanding of the latest retrofit offerings • Software reviews catered to your business needs • Preventative maintenance procedures
. . . AND MORE!
...AND...join us for a complimentary tour of Victory Brewing Company!
Full event information & online registration:
foxmachinery.com/open-house/ Please register by May 15th, 2018.
FEATURING SEMINARS AND DEMOS WITH:
...CONTINUED FROM PAGE 3...
In addition, DDL is very capable of cutting Titanium, Hastelloy, Inconel and other exotics quite well.
What does offer? Currently Mazak Optonics Corp. offers two different laser-cutting machines utilizing DDL technology. One is an affordable tube production laser and the other is a high power, high speed, flat sheet laser-cutting system. The VCL- T100 is an affordable tube production laser that is engineered and produced at our sister company's manufacturing campus in Florence, Kentucky. The VCL-T100 is a compact laser-cutting system that has high-end value and performance while maintaining an economical price point. CLICK THE IMAGE FOR INFO ON THE VERSATILE COMPACT LASER - TUBE 100
Yet the machine that we have seen the greatest impact with is the OPTIPLEX 3015 DDL. This laser-cutting system has changed the game with its impeccable finished parts' edge
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quality and extraordinary cutting speeds. This machine also has our new cutting-edge PreviewG control and drive system which has integrated tech tables to simplify operation. The OPTIPLEX 3015 DDL incorporates our Intelligent MultiControl Torch HP-D and Nozzle Changer technology to directly increase the productivity of the end user by allowing the machine to optimize the torch setup automatically per program. This optimization can dramatically improve cut speeds, increase throughput and require less operator intervention, delivering more predictable processing day after day. CLICK THE IMAGE FOR INFO ON THE OPTIPLEX 3015 ddl
Mazak has made significant investments to develop proprietary DDL technology. We are excited to have this unique advantage exclusive to Mazak. We have established our self as the first to market with DDL and as the leader in DDL development. We will continue to expand its power levels and offering in all ranges of our products.
610.275.4700
Used Machinery
Sales@FoxMachinery.com or call 610.275.4700 for a quote Click on the machine name to read a full description, see photos & request a quote. TIMESAVERS DEBURRING MACHINE 3111-13-0 - 37” wet deburring - Model: 3111-13-0 - Year: 2008 - Condition: Good - Voltage: 230v/3ph/60Hz - Included items: Autolube Click the picture below for more pictures & to request a quote:
Shears____________________________________________________ ADIRA 1330 SHEAR WYSONG 1010RD ACCURSHEAR 1/2 X 12’ ACCURSHEAR 1/4 X 10’ ACCURSHEAR 3/8 X 12’ CINCINNATI 1/2 X 24’ Lasers____________________________________________________ HK 4Kw FIBER LASER - PL3015 Saws_____________________________________________________ DAKE SEMI AUTOMATIC COLD SAW - 3705 BEHRINGER HBP 513A SAW SMID 820 ALUMINUM PLATE SAW Punching Machines________________________________________ WIEDEMANN C-2000I EUROMAC MBX-6-1250/30-2250 PUNCH SUTHERLAND 75 TON PUNCH Press Brakes______________________________________________ PACIFIC 1/4 X 10’ Finishing_________________________________________________ TIMESAVERS DEBURRING MACHINE 3111-13-0 TIMESAVERS 4141-25-00 Cutting Machines__________________________________________ FLOW WATERJET - 6’ X 12’ 2004 METAL MASTER III 6’X20’ ESAB PLASMA ESP200 WITH WATER TABLE CSI KODIAK PLASMA Miscellaneous_____________________________________________ PEDDINGHAUS OCEAN SINGLE SPINDLE DRILL
A PERK AVAILABLE TO ALL FOX MACHINERY CUSTOMERS: Let Fox help you sell your used machinery. Fill out this web form: foxmachinery.com/list-a-machine/ Your Sales Engineer will reach out to have a discussion and we will market it to our customer database for free! Please note: FMA reserves the right to reject machines in poor condition.
~ SUBMIT YOUR OLD MACHINE ~ Fox is compiling images of machines that are as old, if not older, then we are (roughly 50 years+) We would love a photo and a few details about your hard working “dinosaur”. We are happy to publish without directly referencing your company’s name. Please email to marketing@foxmachinery.com by April 30th.
Thank you to the contributors of MachinistMemes.com for this meme.
Request
a q u o t e at
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25 Types of Metal Forming KNOWLEDGE TEST Listed are a wide variety of maufacturing methods - see how many you can match with the correct description below. Good luck!
1 Die-casting 2 Plamsa Cutting 3 Blanking 4 Air Bending 5 Forging 6 Stamping 7 Pressure Casting 8 Notching 9 TIG Welding 10 Bottoming 11 Folding 12 MIG Welding 13 Drawing
14 Punching 15 Coining 16 Shearing 17 Milling 18 Planning 19 Grinding 20 Selective Laser Melting 21 Selective Laser Sintering 22 Machining 23 Roll Forming 24 Die Cutting 25 Mold Cutting
CLICK HERE FOR THE ANSWERS
___ [A] Method using a _______ press to exert pressure so deformation obtains certain mechanical properties, shapes and sizes; it is one of two components of stamping ___ [B] In this method the material makes contact with the punch tip and the side walls of the die but there is not enough tonnage to imprint or thin the material; spring back must also be accounted for ___ [C] In this method the material is conformed to the exact angle of the punch and die by using enough tonnage to do so; the material is thinned by the impact of the punch and die and compressed along the bending surfaces ___ [D] Very similar to using a cookie cutter; the process of cutting out and retaining a piece of metal ___ [E] A shearing process during which a metal scrap piece is removed from the outside edge of a metal workpiece; typically a manually operated, low-production process ___ [F] A blanking technology using a cutting die; the thin film panel is positioned on the base plate - the machine is used to control the blade to cut off the material ___ [G] Known as SLM, a computer controls a high-power carbon dioxide laser which scans the surface of the metal powder - where the laser goes, the surface of the metal is completely fused together ___ [H] Using a cutter with high speed to move the knife on the blank and cut out the shape/characteristics which are needed ___ [I] A form of metal separation accomplished partially by the slicing action of a dropping blade, followed by a clean fracture along the cut ___ [J] A variation of permanent mold casting; this casting method uses air pressure to force the metal through the gating system and the metal casting’s cavity ___ [K] Use a mold cavity to apply high pressure to molten metal; mold is usually made of stronger alloys, process is similar to injection molding ___ [L] In this method of bending the material only comes into contact with the tooling at 3 points; it requires the least amount of tonnage for a bend since the depth stroke, not the tooling, determines the angle; spring back must be accounted for ___ [M] In this method, a gas is employed to shield the material being welded in order to prevent it from being affected by oxygen and other natural elements ___ [N] Also called face milling; machining method of cutting the workpiece with the planer tool in the horizontal linear reciprocating motion; It is mainly used for the contour machining of parts ___ [O] Known as SLS, uses a laser as the power source to compact and form powdered material through heat ___ [P] The process of removing unwanted material from the block of metal to get the desired shape ___ [Q] Most commonly performed with a press brake, a set of dies are used to pinch the metal until it forms a desired crease ___ [R] A process that cuts through electrically conductive materials by means of an accelerated jet of hot plasma ___ [S] A type of blanking technology, the preformed film is positioned on the punching male die and retains the 3D shape of the product and match the mold cavity ___ [T] Also called Cold Drawn, this method applies external force to the front end of the pulled metal; the metal billet is pulled from the die hole to obtain the corresponding shape and size of the product ___ [U] An arc welding process that uses a non-consumable tungsten electrode to produce the weld ___ [V] Uses a series of continuous frames to make the stainless steel into a complex shape; the roll type of each rack can deform the metal continuously until the desired final shape is obtained ___ [W] Refers to the process of removing excess material from the workpiece by abrasive materials and tools ___ [X] Method similar to punching, except the material is not cut; the die used creates a raised portion of material rather than penetrating entirely ___ [Y] The forming of workpiece with a desired shape and size by applying an external force on the plate, strip, pipe, and profile to produce plastic deformation (or separation) by pressing machine and die
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