Sawing productivty internetinis žurnalas

2016 MARCH

SAWING BY THE APP TECHGEN MEDIA GROUP’S INAUGURAL ISSUE OF SAWING PRODUCTIVITY

Innovation Makes the Difference

Innovative Starrett technologies.

Manufacturers, builders and craftsmen worldwide have depended upon saws and precision tools from the L.S. Starrett Company to ensure the consistent quality of their manufacturing processes.

The Starrett name on saw blades means exceptional quality, innovative products and expert technical assistance. With strict quality control, state-of-the-art equipment and an ongoing commitment to producing products with superior quality, the Starrett line continue to be the most accurate, robust and durable saws available.

starrett.com

Innovation Rules

Dear Readers: It’s with great excitement that we, the team at Techgen Media Group, announce the inaugural issue of Sawing Productivity. We’ve been gearing up for this day for some time now, and we hope that this new addition to our family of publications is a valuable resource for you.

Since the first day that Techgen opened its doors, the overriding goal has been to help readers make the most of their fabricating operations. That goal was first realized in the pages of FAB Shop Magazine Direct and continued with the publication of Shop Floor Lasers and Welding Productivity. Today, the team at Techgen is proud to expand our coverage of the metals fabricating industry with Sawing Productivity.

The Sawing Productivity special edition will reach a total combined circulation of almost 220,000 subscribers in the United States, Canada and Mexico. The majority of our readers have sawing operations in their facilities, so it made perfect

sense to put a spotlight on this important aspect of manufacturing.

Five times each year, readers can expect articles that discuss new strategies and products that are being touted by the biggest players in the sawing game. To make sure that our readers are getting the most out of the new publication, however, we invite input from the people who matter the most to us: the fabricators and manufacturers that are – day in and day out – working hard to make their operations as productive and profitable as possible.

So send us your story ideas. Or tell us about the challenges you face, and we’ll try to track down a solution that fits.

E-mail me at amiller@techgenmedia.com.

Happy reading!

ABBE MILLER Editor-in-Chief Sawing Productivity

March 2016

2

Sawing Productivity P.O. Box 516 Plainsboro, N.J. 08536

Sawing Productivity is a registered trademark of Techgen Media Group. We publish quarterly. All rights reserved under the U.S., International and PanAmerican Copywrite Conventions. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means such as mechanical, photocopying, electronic recording or otherwise, without the prior written permission of Techgen Media Group. Contact us at 732.995.6072 for permission. Produced in the U.S.

EDITORIAL Abbe Miller, Vice President/Group Editorial Director phone: 847.749.6956 email: amiller@techgenmedia.com Susan Woods, Managing Editor phone: 847.973.2271 email: swoods@techgenmedia.com Jimmy Myers, Senior Editor phone: 503.964.7519 email: jmyers@techgenmedia.com Molly McCormack Moody, Editorial Assistant phone: 262.501.6897 email: mmoody@techgenmedia.com Justin Stivers, Director of e-Media email: jstivers@techgenmedia.com Kyle Grossi, Office Manager/Accounting email: kgrossi@techgenmedia.com

SALES Alan Berg, Vice President/Sales phone: 732.995.6072 email: aberg@techgenmedia.com Neil Kelly, National Sales Manager phone: 610.584.5560 email: nkelly@techgenmedia.com EDITORIAL ADVISORY BOARD Joanna Wilcox, Marketing Manager HYDMECH Doug Harris, President and CEO HE&M Inc. PRODUCTION Angle180 Inc. phone: 847.439.6226 email: sarunas@angle180.com

VERTICAL Heads Up.

Cosen has been manufacturing quality bandsaws for 40 years.

SVC-670DM

Vertical Tilt Frame Double Miter-Cutting Bandsaw (ALSO AVAILABLE: MVC-670DM)

Discover how our line of manual and semi-automatic, tilt-frame,

miter-cutting, vertical bandsaws can boost your metal cutting productivity today.

D O N ’ T TA K E O U R W O R D F O R I T

‘‘An absolute game-changer for our

machine shop. Our saw output has more than doubled over the output of our previous saw. We’ve had to figure out new ways to manage the cut material now that we have so much more of it! ’’

– Dan Kaiserian, Operations Manager, Sonny’s

(888) 720-5371 www.vertical.cosensaws.com

Pat Mooney Sells A Lot More Than Saws.

We Sell Four Generations Of Successful Partnerships.

Trusted partnerships

We have established trusted partnerships with all our Customers, Suppliers and Distributors. Our satisfaction rate is one of the highest in the industry.

Four generations of quality and service

For four generations Pat Mooney has provided uncompromising product quality, technical and part replacement service, and over all expertise in saw technology.

Expanded facilities

We have recently expanded, tripling our warehouse and technical support facilities. We can better provide you the saws, service and solutions you require.

With Pat Mooney Saws you are not only getting the perfect cut, you are getting the perfect partner and answers to your evolving needs.

patmooneysaws.com | 800.323.7503 | email: sales@patmooneysaws.com

FEATURES 5

2016 MARCH

SAWING BY THE APP Application- and material-based machine designs for production sawing

9

STOP, LOOK, LISTEN A sawing equipment manufacturer is on a mission to rid workshops of tape measures, one automated solution at a time

15

COLD SAWS, HOT AUTOMATION Scotchman Industries, a leader in industrial saw engineering, had humble beginnings in South Dakota, but is now a worldwide player

Cover image courtesy of Behringer Saws Inc.

DEPARTMENTS Editor’s Letter Industry News

5

9

15 March 2016

4

SAWING BY THE APP Application- and materialbased machine designs for production sawing

by Richard Klipp, president, Behringer Saws Inc.

March 2016

5

T

here’s an old saying that’s true – you can’t fit a square peg into a round hole.

Similarly, you cannot expect exceptional non-ferrous sawing with a saw designed to cut standard steels.

In a perfect world, one saw would offer the highest sawing performance for every possible type of material.

Although there are saws that can be quite versatile, realistically speaking, there is just too great a range of material grades for one saw to cut them all exceptionally well. For example, while the best sawing speed for Inconel on a band saw may be at 120 sfm, the best speed for aluminum may be at 4,500 sfm.

DESIGNED FOR THE JOB A job shop that handles a variety of work and materials should strive to find a saw that handles a wide range of materials and cuts them all reasonably well. Of course, the understanding (or tradeoff ) is that the speed of cutting, blade life, cost per cut and cut quality over the range of those cuts will not be as good as they would be if they were processed on a saw specifically

designed to cut a particular group of materials.

However, when the focus is on production sawing of a certain material range, then the objective should be to find the sawing solution that is based on a machine designed for the most effective sawing of that material. This means the machine base, framework, gearbox, motor, controls, blade size, blade guidance, cooling process, chip collection and many other variables should be designed to offer the most cost-effective and efficient sawing. In other words, not all saws are created equal, and not all material sawing processes are the same.

For a saw to be efficient and costeffective for cutting non-ferrous materials, it needs to be built specifically for the application from the ground up. It needs to incorporate a number of features that are unique to effective processing of non-ferrous materials, including the motor sizing and its speed and torque range. It also needs to have a very rigid base to build on, proper wheel and blade sizing, a means to efficiently deal with the

Behringer’s HBM series highperformance automatic band saws are good for high volumes and are particularly well suited for steel, Inconel, titanium and other non-ferrous metals.

The VA-L 560 is a good example of how circular cold saws are effective for highthroughput sawing of aluminum.

Large horizontal band saws from Behringer feature roller conveyors and come as tabletop machines or gantry versions with traversing saw frames.

March 2016

6

lighter chips generated in non-ferrous sawing, coolant application, ease of maintenance and so on.

This same philosophy holds true whether you are talking about band sawing or circular cold sawing, as the theory and design processes are applicable to both technologies. For example, simply modifying a steelcutting circular-saw gearbox to allow for faster blade speeds while keeping all other machine functionality the same will just not work effectively for aluminum. Instead, the design must take many other variables into consideration, such as clamping pressure, blade separation features and a faster feeding gripper system.

SAWING SCENARIOS A similar scenario holds true for the sawing of Inconel and other

superalloys on a band saw. The most optimal sawing of these materials requires an extraordinarily rigid design that can handle the required blade size and blade tension and offer excellent vibration-dampening characteristics.

It also needs to include a positive and consistent downfeed system, be able to sense pressure at the blade and react accordingly, monitor and compensate for square cutting, and offer sufficient coolant application to offset the high heat that is generated in this process.

Again, there are saws available that are versatile and forgiving, and allow for cutting a wide variety of materials. But, there is simply no one saw that does it all at the highest possible performance levels. An aluminum production shop needs a saw that is designed from the ground up for that application, while

“For a saw to be efficient and cost-effective for cutting non-ferrous materials, it needs to be built specifically for the application from the ground up.�

SAWING SUPERALLOYS According to The Minerals, Metals & Materials Society, the term “superalloy” appeared after World War II to describe a group of alloys used to produce turbosuperchargers and aircraft turbine engines. These applications, which have expanded to include aircraft and landbased gas turbines, rocket engines, and chemical and petroleum plants, require high performance at high temperatures. “[Superalloys] are particularly well suited for these demanding applications because of their ability to retain most of their strength even after long exposure times above 650°C (1,200°F),” the MMMS explains. “Their versatility stems from the fact that they combine this high strength with good low-temperature ductility and excellent surface stability.”

Superalloys fall into three main categories: nickel-, iron- and cobaltbased alloys. Inconel, which is a nickel-

Inconel is a material of choice when high strength and low-temperature ductility is needed.

based superalloy, was created for the development of the first jet engine – another example of superalloys’ ability to endure high temperatures.

When cutting this high-strength material, a high amount of heat is generated, and because of the low thermal conductivity of Inconel, the heat generated in the cutting process can be transferred from the material to the cutting tool.

To manage the heat generated in the process, coolant must be employed.

To simplify the task of choosing a coolant to use, Behringer provides its customers with recommendations that offer the best coolant to use according to the saw in operation. When effective cooling is employed – especially with superalloys – tool wear can be kept to a minimum, allowing fabricators to realize high feed rates and shorter cutting cycles as well as increased tool life.

March 2016

7

“When it comes to the production sawing of specific materials, learn about the saw’s design and technologies and don’t settle for a ‘this saw excels in all applications’ pitch.”

an Inconel, titanium, superalloy facility will want a whole host of different technologies and features in a saw that will be cutting these exotic materials.

When it comes to the production sawing of specific materials, learn about the saw’s design and technologies and don’t settle for a “this saw excels in all applications” pitch.

KEEPING PACE An additional consideration of efficient non-ferrous sawing is the material handling component. For example, machines that are designed to cut aluminum saw much faster, so it’s imperative to keep up with the pace of the equipment and ensure that material is being fed into the saw at an effective rate. With cut times that are dramatically

faster on specialty saws, the total part cycle time can only be as good as the ability of the system to get material in and out of the saw just as efficiently.

Typically, systems can be fully integrated into the saw to handle everything from powered roller conveying to cross transporting and bundle clamping. Cutting to length, ejection and sorting are also standard for most material handling systems.

BEHRINGER SAWS INC.

ADVICE ON ALUMINUM Aluminum is one of the most versatile materials on the planet. From beverage cans to automobiles, it’s the stuff of everyday life. Because of its unmatched qualities, however, it’s also found in some of the world’s most high-tech applications where strength and durability are paramount.

Weighing in at only about a third that of steel, products can be thicker and stronger yet lighter weight when they’re made out of aluminum. According to the Aluminum Association, “Depending on the alloy and processing technique used, pound for pound aluminum can be forged to be just as strong if not stronger than some steel.”

Because of its inherent physical qualities – malleable, ductile and lightweight – fabricating aluminum can be fairly easy. In that same breath, however, the soft nature of aluminum requires a different approach.

To keep from scarring the metal, equipment cleanliness is important.

When metal burrs and particles are present on a piece of equipment, the surface of the aluminum can be susceptible to scratches and other damage. Therefore, fabricators must understand how to efficiently deal with the chips created when sawing aluminum to avoid surface damage.

“When sawing plate, be sure to remove saw chips and cutting coolant-lubricant from the top and bottom surface before stacking the sawn plate on any surface,” explains the Aluminum Association. “When sawing a number of plates simultaneously, it is important to separate the stack as soon as practical to allow for removal of saw chips that might have been entrapped. Coolantlubricant must also be removed to prevent staining.”

March 2016

8

STOP, LOOK, LISTEN

A sawing equipment manufacturer is on a mission to rid workshops of tape measures, one automated solution at a time

by Jimmy Myers, senior editor

S

pencer Dick ran a furniture making business for many years before starting TigerStop LLC. An inventor and engineer at heart, Dick noticed something that really bothered him during his years in business - he would watch employees on the shop room floor laboriously set manual stops for every different size part that required a cut.

“It was just the most frustrating thing to watch,” says Dick of the inefficient work process. “So I set out to build my own machine to solve the problem.”

Dick began the project in his garage, TigerStop’s first home, and brought on a couple of key team members to help him build a prototype for an automated stop. He refers to it as a “digital tape measure” that would allow operators to make accurate cuts at something in the area ±0.004 in., day in and day out.

“We got that (prototype) to run for 15 minutes before I had to pack it up and take it to a trade show in Atlanta,” Dick explains.

Dick told his wife they needed to sell five units at the tradeshow or he’d have to get a new job and leave his pet project behind. He’d already made significant investments into the project and was about to become unglued when day three of the four-day show rolled around and he’d not sold a single unit.

“My wife sent me off to lunch and said, ‘you’re doing no good here,’” he remembers.

By the time he got back, she had sold five units. By the end of the show, they had sold 17 units, paid in full, and another 17 were on order.

“That was 22 years ago and it’s just been growing ever since,” Dick says.

THE STOP “Fast and Accurate Every Time.”

Those words on TigerStop’s website paint a fairly clear picture of what the company’s products do. Setting manual stops is slow and tedious. It also leaves you prone to errors and inaccuracies even with the most experienced operator.

March 2016

9

TigerStop is an automated stop. The operator simply punches in the cut list and the TigerStop moves to position.

This saves a lot on labor because it is far faster than measuring and setting a manual stop. It also saves on material because it is far more accurate than a tape measure.

In fact, Dick says for every tape measure on a shop room floor, a company can expect to pay a lot in losses due to inaccurate measurements that result in poorly cut parts in need of rework.

“The best place for a tape measure is in your pocket,” Dick says smiling.

ENTER THE 2000 With more than 30,000 systems in use in manufacturing environments around the world, TigerStop has grown to include a family of add-on automation products that can stop, pull, push or position material for multiple applications including sawing, punching, drilling and boring.

Mike Anderson, systems product manager at TigerStop, says the company has grown from its add-on automation products to include some

fully automated saw stations, the latest of which is the TigerSaw 2000.

The TigerSaw 2000 is an automated saw station for cutting non-ferrous metals such as aluminum. It comes with the company’s proprietary Dynamic Optimization software that achieves maximum yield by nesting parts. That means it compares the cut list to the material length to determine which parts to cut in which order to provide the least amount of waste.

Anderson says the automation in the TigerSaw 2000 is all about accuracy and efficiency. In fact, TigerStop customers have shared that when TigerStop equipment enters the work area, turnover and job satisfaction for the person doing the cut-to-length jobs improves drastically.

“Believe it or not,” Anderson says, “in this day and age, a lot of employees can’t read a tape measure.”

Operators simply enter the length of raw material being processed, the number and length of finished parts, and the system automatically determines how to make those cuts with the least amount of scrap.

Spencer Dick founded TigerStop in Vancouver, Wash., two decades ago. His company now has a facility in Holland serving Europe.

TigerStop’s push-button panel gives operators an easy way to input material sizes, length of cuts and amount of cuts.

March 2016

10

Aut omate d S a w S t a t i o n fo r A l u mi n u m

Adjustable Cutting Envelope Best-in-class capacity adjustable cutting envelope increases the range of material profiles you can cut.

Adjustable Pneumatic Clamping Pneumatic clamping won’t damage fragile material or material with odd profiles.

Available with multiple clamping options.

Patent Pending Lube Mist Lube mist system follows the blade, delivering coolant right at the cut, for a longer blade life and better quality cut with dry chips.

TigerStop LLC www.tigerstop.com • 360.254.0661

Call for more information (360) 254-0661

Visit us at www.tigerstop.com/products/tigersaw-2000

The TigerSaw 2000’s adjustable cutting envelope assists in accurately cutting materials of different shapes.

Dick says many companies in the metalworking industry look at scrap as a profit center, thus giving them little incentive to cut back on the amount of miscut parts being produced. However, aluminum scrap for example, is sold for about six times less than purchase price.

“It’s an uphill battle in terms of how people think in the metals industry,” Dick says of the situation, “but it’s beginning to flow in that direction.”

LOOKING FOR DEFECTS Defects can occur when the bulk material, such as long lengths of aluminum, are strapped down and shipped. The pressure from the straps, shipping damage and forklift stabs, for example, deform areas of the aluminum, which then become unusable.

Because those defects are hard to eliminate, TigerStop has a solution to keep them from finding their way onto a part or product. Called Crayon Marking, an operator simply marks a defect with a crayon and the software scans the crayon marks, cutting around defects and optimizing the cuts

between based on the cut list to make more efficient use of the material.

Simon Spykerman, director of marketing at TigerStop, says the industry is evolving and that it takes innovative minds to stay out in front of competitors. The software has gotten more sophisticated and TigerStop has become more than just a company that produces stops. With Dynamic Optimization, coupled with the accounting of defects, Spykerman says they’re giving clients the ability to get the most yield out of their materials, including non-ferrous metals, wood and plastics.

“Even with the defects,” Spykerman explains, “you can optimize your yield without having to do all the math.”

TECH SPECS TigerSaw 2000 comes with an adjustable cutting envelope that allows for a variety of profiles from bundles to single pieces. It can be fitted with various blade sizes and the saw arbor can be adjusted forward and backward to provide a larger cutting

March 2016

12

envelope for the given saw blade diameter.

Clamping options include both horizontal and vertical pneumatic clamping to allow proper clamping of most profiles. Ink Jet Printing for up to five fields on each finished piece allows the operator to batch jobs of the same profile and easily sort the parts on the back end.

Furthermore, the TigerSaw 2000 can be outfitted with a TigerStop, TigerTurbo or HeavyDuty 2 automation system.

• The TigerStop allows operators to push up to 120 lbs. and the maximum length of material is 30 ft.

It has a 32-mm reinforced belt drive and uses a DC servomotor with optical encoder.

• The TigerTurbo can be fitted to the solution for heavier material. It has a weight capacity of 840 lbs. with roller tables and 350 lbs. without rollers and works with materials up to 40 ft. long. It is outfitted with an AC servomotor with optical encoder.

• The HeavyDuty 2 has a push capacity of 2,100 lbs. with roller tables and 490 lbs. without. It can

work with materials up to 108 ft. long. It has a rack-and-pinion drive and an AC servomotor with optical encoder.

Spykerman notes that one of the most unique features on the automated system is the patent-pending lubricating mister, which actually follows the saw blade as it moves through the cut. Most saw systems apply lubricant all over the blade, hoping some gets to the cutting point.

“But by delivering directly at the cut point you get an amazingly smooth and powerful cut, but it also extends blade life and generates dry chips so there is no messy cleanup or swarf,” Spykerman says.

LISTENING TO THE INDUSTRY Job shops throughout the country are experiencing issues associated with the skilled labor shortage. Because of the skills gap, TigerStop has listened to what industry leaders are saying and is doing its part making automation easier by using hardware and software that is simple and familiar.

Most Americans are accustomed to using touchscreens, which is why TigerStop developed the TigerTouch in 2015. It’s a touch-screen workstation

The easy-to-operate automated solutions from TigerStop allow operators to reduce scrap and make more accurate cuts.

The TigerSaw 2000 has a variety of automated features that can offer a return on investment in six months.

March 2016

13

“We keep it simple.

Otherwise, you’re not going to get good results. That has been our theory from day one; take out the fussiness and the things people dislike doing.”

Spencer Dick, founder, president and CEO of TigerStop Inc.

THE SOLUTION PREFERRED

BY METAL FABRICATORS!

QUALITY! ACCURACY! DEPENDABILITY! VERSATILITY!

American manufacturer and importer of quality machinery.

GUARANTEED!

50514-CM IRONWORKER

Miters from 90° to 45° Best-in-the -Business

WARRANTY !

CPO 350 LT COLD SAW

More options and accessories keep costs down and productivity and profits up!

AL100U-02 TUBE & PIPE GRINDER/NOTCHER

Call TODAY to set up a DEMONSTRATION at your work site!

SEE US AT...

Call Toll Free 1-800-843-8844 or Call Direct 605-859-2542 • Fax 1-800-843-5545 or 605-859-2499 www.scotchman.com • info@scotchman.com • Scotchman Industries Inc., P.O. Box 850, Philip, SD 57567

running on Surface Pro 3 – something that many operators are familiar with.

TigerTouch means operators can put away crammed clipboards and manage everything from the machine.

It’s an add-on that allows users to store thousands of cut lists, view dynamic optimization as it is happening and store easy-to-access profiles.

BOOTH S1923

LEASING AVAILABLE

with a facility in Holland. Dick says the company carries no debt and will continue to innovate solutions.

“We keep it simple,” Dick explains about their approach. “Otherwise, you’re not going to get good results.

That has been our theory from day one; take out the fussiness and the things people dislike doing.”

THE TIGERSTOP ETHOS TigerStop operates out of a 30,000-sq.ft. facility in Vancouver, Wash., and has expanded to the European market

TIGERSTOP LLC

March 2016

14

COLD SAWS, HOT AUTOMATION Scotchman Industries, a leader in industrial saw engineering, had humble beginnings in South Dakota, but is now a worldwide player

by Jimmy Myers, senior editor

March 2016

15

P

ositioned in the heart of cattle country in South Dakota, Art Kroetch began producing what ranchers around him in the early 1960s needed – gates and chutes, pickup stock racks and corral panels. A few years later, under the name Scotchman Industries, Kroetch purchased a patent for a hydraulic ironworker, a machine that implemented hydraulic pressure using 35 tons of power to shear, punch and bend metal, thus building a solid foundation for what the company has become today.

Scotchman Industries Inc. manufactures metal fabrication equipment and custom tools and accessories. While the company began with a focus on ironworker machines, it has firm footing in circular cold saws. Steel manual and semi-automatic saws, non-ferrous saws, non-ferrous upcut saws and automatic saws come in standard varieties through Scotchman, but most orders are made with customizations.

Mike Albrecht, national sales manager at Scotchman, says one of the biggest perks the company offers is the ability to customize – broadening the product line to fit into specialized applications.

“Everybody wants something a little different,” Albrecht explains. “It seems like every order we get anymore isn’t just a standard sawing machine. We do a lot of varieties of customizations to fit a specific need. If it doesn’t fit the customer, it doesn’t do any good to try to sell it.”

Albrecht says anytime a new application comes up, Scotchman’s research and development team is working to fit a saw into that application.

“We’ve turned down a few client requests,” he says. “Not a lot, but there are some things that are too far out there that can’t be done. Most of the time I would say there’s nothing that can’t be done, but maybe it can’t be done at an affordable price, and that’s kind of the key.”

CUSTOMIZATION PROCESS Most customers seek customized sawing equipment because of a special material profile that can’t be crushed or an odd tube that can’t be correctly pushed through a machine and cut, Albrecht explains. This is what necessitates a customized feeding or clamping jaw to accommodate the

Scotchman Industries’ new CPO 315 HFA CNC saw is fully programmable, which means it can produce cut lengths quickly and accurately. Maintaining a length tolerance of ±0.006 in., users can cut tubes and pipe up to 3 1/2 in. dia. and solid material up to 1 3/4 in. thick.

part, which is the most frequently requested customized piece that Scotchman is asked to build.

parts so Scotchman engineers can see exactly how they need to customize the equipment.

Customized orders start with a one-onone conversation between the client and Scotchman, whether through a network of dealers or through individual factory representatives around the country. Customers have also been known to send in sample

“We’ll go out to a saw and try to cut it and match it up,” Albrecht says of the sample parts that are either sent to Scotchman or tested at the customer’s site with mobile equipment. “I don’t want to sell somebody a saw if the application is not right.”

March 2016

16

888-362-5572

EFFICIENCY

400 -AV

Featuring automatic indexing with an ALL NEW servo-driven ballscrew shuttle vise, pneumatic head lift and hydraulic feed control. An economical, general-purpose saw to meet your needs without straining the budget.

“

DC-33

The features you get w for the price, I found to I have to say—it was o purchases I’ve made.”

Ron Hayes, Owner The Blower Shop - Sim Builds high performan

Solutions For All Your Sawing Needs

Y MEETS AFFORDABILITY

,

800-SNC B4611

The DoALL 800-SNC is now available with a 12’ long stroke shuttle. Part of the StructurALL® family of machines, it is an affordable Numeric Controlled (NC) angle cutting saw that increases flexibility and provides greater efficiency for general purpose sawing.

30NC

with the machine (DC-330NC) o be the best value out there. one of the best machine .”

mi Valley, CA nce superchargers

888.362.5572

NEW!

www.doallsaws.com

Scotchman Industries’ easy-to-use touch screen improves workload efficiency.

AUTOMATION NATION Albrecht notes that trends are few and far between in the sawing industry, but an ongoing one involves a need for increased automation.

“We’ve always had some level of automation,” he says, “but now everybody is weighing against automation and increased productivity with less cost. Levels of automation are definitely increasing.”

Scotchman began distributing circular cold saws for BEWO of Holland in 1983, and began building saws in a joint venture with BEWO in 1988. The company then bought BEWO’s interest

in 1993. Four years later, Scotchman took a leap forward into automation with the introduction of the Hitch Feed Automatic (HFA) and Roller Feed Automatic (RFA) circular cold saws.

Just over a decade ago, Scotchman bought a company called Advanced Measuring Systems to integrate manual length and stop gauging systems that could be used for most metal and woodworking jobs. This facilitated the introduction of a line of programmable feed systems and programmable stop systems in 2006, which gave clients the ability to eliminate operator error and increase production.

The CPO 315 HFA CNC saws are equipped with interlocking safety hood, mist coolant, programing for up to four separate cut lengths per job, and many other features.

One of the newest saws the company is producing today is the CPO 315 HFA CNC fully automated saw. It offers touch-screen controls, an interlocking safety hood, mist coolant, programing for up to four separate cut lengths per job, 50-program job storage and unlimited shuttles, among other features.

“It gives you total CNC control to program in the length,” Albrecht says. “It allows you to easily enter the quantity of cut and length of each part.

You have the ability to cut multiple cut lengths as well as unlimited lengths of cut. This saw has to be the easiest saw on the market to program.”

The CPO 315 HFA CNC saws are easy to program and give the operator the ability to cut multiple cut lengths and unlimited lengths of cut.

March 2016

18

“Whether you’re cutting metal in a welding shop out in the middle of South Dakota or you’re working in the Metropolitan Opera House in New York City, there’s a place for a circular cold saw.”

Mike Albrecht, national sales manager, Scotchman Industries Also new is the CPO 315 RFA machine that uses a loading system that takes a supply track, loads it full of material and then loads the material onto a rack and feeds it through to set lengths where cuts are made. Albrecht says the return on investment for this low-cost, fully automated system can be as low as two to three years.

LANDING AN UPPERCUT Scotchman offers a handful of standard upcut circular cold saws for largecapacity cutting of non-ferrous materials.

The SUP-500 NF is designed for a 20-in. saw that can handle a 7-in.-dia. round or an 11.75-in.-by-5-in. rectangle.

For larger material needs, the SUP600 NF has a 24-in. blade that cuts up to a 9-in.-dia. round or a 15-in.by-6-in. rectangle. Also available is the GAA-500 90, which has a shuttle feed design for straight 90° cuts on large diameter profiles. It cuts up to a 6-in.-dia. round or a 10-in.-by-3-in. rectangle.

One way of meeting that increased level of automation expectancy came in 2013 when the company expanded its line of sawing equipment by bringing in a non-ferrous upcut circular cold saw, which is imported from Spain.

“Scotchman was looking to produce our own upcut saw until we met a partner in Spain,” Albrecht says. “It’s a good family company like our own. It was a good fit and we joined together on a joint venture to market the product in North America.”

TARGET AUDIENCE Albrecht says prospective clients have the convenience of an on-site demonstration of the company’s sawing capabilities at their disposal.

Sixteen sales reps throughout the country are equipped with trucks or trailers full of the company’s products.

“They can pull into a customer facility and make a cut. It’s a huge plus for the customer because they can justify the

purchase before they actually have to pull the trigger.”

Scotchman’s target audience is pretty much anybody who cuts metal, Albrecht says. From hobby shops to Fortune 500 companies, the company has delivered – and it has delivered worldwide.

As an example of the variety of clients it services, Albrecht recounts one of his first jobs for the company around two decades ago. He was called to the Metropolitan Opera House in New York City, where on the third floor of the

building sat two Scotchman circular cold saws and one ironworker used to create elaborate sets for plays and operas.

“That just shows you,” Albrecht says, “whether you’re cutting metal in a welding shop out in the middle of South Dakota or you’re working in the Metropolitan Opera House in New York City, there’s a place for a circular cold saw.”

SCOTCHMAN INDUSTRIES INC.

March 2016

19

INDUSTRY NEWS BEHRINGER SAW INCREASES THROUGHPUT Behringer Saws Inc. has delivered its HBE 321A dynamic horizontal band saw to Spanco Inc. Spanco uses the machine to saw tube sections for fabricating cranes. It has helped increase throughput by roughly 20 percent due to faster cycle times and reduced maintenance time. The saw has a rigid, dualcolumn, cast-iron frame and its servo-driven downfeed control automatically adjusts blade pressure, creating optimal balance of feed rate and pressure. Its electrically powered ballscrew-driven material feed gripper eliminates backlash and ensures precise material positioning.

COSEN’S CLOUD-BASED PREDICTIVE SYSTEM Cosen Saws introduces MechaLogix Cosen Predictive Computing, a cloudbased system for the metalworking and fabrication industry with a feature that monitors saw blade performance. This new technology can accurately forecast a complete breakage as well as the number of remaining cutting hours left before a saw blade dulls and is no longer cutting with precision. It generates real-time performance data and reports issues such as excessive vibration, overheating and changes in fluid line pressure.

March 2016

20

SCOTCHMAN ADDS DRILL TAP OPTION Scotchman Industries Inc. offers a drill tap option for its GAA-500 90 automatic upcut circular cold saw. The saw is for cutting non-ferrous materials at 90° up to 6 in. for square and round material. The drill option gives the saw the ability to drill and tap holes up to 20 mm with a single spindle drill, or by adding a multi-spindle drill, add multiple holes at one time. The CNC option along with the drill option allows positioning a hole or set of holes on a single axis on the workpiece and then cutting to length.

NEW BUSINESS MODEL FOR CONTINENTAL MACHINES Continental Machines Inc., manufacturer of DoAll Sawing’s band saws, announced a two-year plan to transition from a manufacturing-based company to a service-and-distribution-based company to better address customer demand. During the transition, CMI will continue to offer its current line of DoAll products while adding new sawing machine models. It will also expand availability of replacement parts on its online store and increase technical support for the entire product line.

KASTO SAW CUTS TUBULAR MATERIAL Kasto Inc. introduces the KASTOwin Tube A 5.0, a fully automatic band saw for cutting tubular material in an upward motion with a carbide-tipped blade.

The upward motion helps reduce blade wear. It features a cutting range of 10 mm to 500 mm. Using a frequency-controlled drive, cutting speed can be adjusted continuously between 12 m per min. and 150 m per min. The vice and saw feed are equipped with zero-play linear guides, and the ballscrew spindle drives ensure controlled cutting feed rates.

March 2016

21

DOALL SAWING EXPANDS PRODUCT LINE DoAll Sawing’s Continental Series offers five high-production, semi-automatic horizontal band saws for operations that do not require indexing or automatic cutting cycles. Semi-automatic capacities on rectangular workpieces range from 11.75 in. by 11.0 in. up to 39.4 in. by 31.5 in. Once the operator sets the desired feed rate, blade speed and initial vise opening and the cut is complete, the band shuts off and the head returns to the upright, open position and locks. The operator must then manually reposition the material for another cut.

Because the operator is not pressuring or overloading the saw blade during a cut, blade life and accuracy are increased.

SIMONDS REINTRODUCES BAND SAW BLADES Simonds Saw reintroduces two bimetal band saw blade lines that combine new features and manufacturing methods to increase cutting rates in production metal sawing applications. The SiClone blades, for cutting alloys, and BlockBuster blades, for high-production sawing where cut accuracy and blade life are important, have new rugged backing steel, heat treatment for long life, new tooth-tip metallurgy and treatment, and a new finishing process for blade strength. The blades are available from 2-in. to 3-1/8-in. widths.

March 2016

22