Tuesday, June 4, 2019

A Detailed Overview About Achieving Better Bend Accuracy on A Press Brake

Compensation of the Deflection in the table of the press break and the beam is an essential thing in press brakes which guarantees proper repeatable results when you implement the load on it. Without compensation of deflection, it's likely that a workpiece would have some form of deformation on its center when bent along the full length of the press brake. In order to keep the bend angle uniform over the full length of the press brake part, it needs a crowning system.

In this age of complex parts, quick turnaround, and short batches, crowning helps to maintain efficiency and repeatability. Let's see how in high-tonnage applications crowning helps to produce straight bends in high-tensile materials.

What is Crowning?

New age modern press brakes like Amada Press Brakes use a servo-hydraulic system in which a closed-loop system controls the position of the ram. At the corner of the beam, a position measuring system monitors the movement and accuracy of the beam. It does this by activating the left and right valves at the top of the position.

During the bending period, the servo-hydraulic system makes sure that the piston at the ends of the beam reaches the programmed position in the machine control and finally resulting in the correct bend angle. Because press brakes tend to deflect under load, especially in the center of the machine between the pistons. It is an angle in the center of the press brake. Without intervention, it would cause the bend angle to vary over the length of the press brake.

For the best results from crowning, it is advisable to use quality and modern press brakes. You can get them at cheaper rates as well by searching for "Amada Press Brake for Sale."

The Origin

In order to enhance the bending accuracy, it is important to have a crowning system which forms an opposite force to offset the deflection of the beam and the table. With the crowning system, you can ensure that the ram and table are parallel during bending.

Plus, crowning is not something new in the business. It has been in the market since the 1970s. Each day its demand is increasing with high-tensile-strength steels. Before its existence, manufacturers had to pregrind the curve into the press brake table to offset about 75% of the deflection. In the present scenario, systems are more advanced. Operators can enter the sheet thickness, die opening, and material tensile strength data into the machine using crowning systems. By using the press brake's hydraulic system and crowning together, it can provide an accurate bend angle with minimum operator intervention.

The Process

You can utilize Crowning with the press brakes of 80-ton in weight, 8 ft or larger in size. You can apply it to lower-tonnage press brakes as well. However, it depends on the length of the press brake table and its application. If the distance is longer between the uprights, the higher the machine deflection. Simultaneously, the higher the tonnage of the machine, the more the need for deflection compensation arises. To bend the thick and thin materials, a crowning system is the best option always.

There are two types of crowning available. Hydraulic and CNC mechanical wedge-style. You can purchase a CNC mechanical wedge-style crowning system as an add-on to a press brake through a manufacturer or tooling supplier. The CNC mechanical wedge-style crowning system can also be treated as one of the LVD press break parts. Hydraulic crowning is based in the machine. At the time of selecting between these two types, keep the cost comparison in mind but give more weightage to accuracy and efficiency.

You can apply the hydraulic crowning to the cylinders which adds pressure on them during the process to maintain the machine deflection. These systems do not apply the crowning process across the entire bed of the machine. Instead, the deflection amount for which the crowning system adjusts for is dependent on the cylinder location. Some of the hydraulic systems use only a central cylinder or a three-cylinder system. It provides crowning over 60 percent of the bed.

The hydraulic cylinders use the same line. As a result of it, no cylinder receives the full crowning force. All the hydraulic cylinders experience this force regardless of the numbers.

Critical for Accuracy

Crowning systems are more precise and capable these days. They can place more crowning in certain areas of the press brakes. As the manufacturing landscape changes, the crowning system has become a critical element to have in order to achieve accuracy and operations.

Learn how you can achieve the high tensile and accurate bending results with the help of the different type of crowning processes with the press brakes. The crowning process is more critical for the LVD press brake parts , tridem, quadem which combines various press brakes of similar or dissimilar tonnage in a synchronized configuration. They synchronize the cylinders to ensure that there is a constant straight- line movement in the machine.

Monday, June 3, 2019

A Layman's Guide to Computer Cooling Fans

Cooling fans are important for any computer. If you are assembling a PC system with all the modern components, at least one cooling fan is necessary. When you surf online you would find a number of varieties & brands in cooling fans such as Fanuc cooling fans and more.

But as a beginner, it is important to cut through the marketing jargon and select the right product for your computer. This guide would explain all such things in detail to help you choose the right cooling fans for your computer system.

Consider Size & Placement

One of the first concerns is their size. Because it depends on the overall system size. Most modern systems use 80, 120, Or 140 mm fans. In some exceptional cases, CPU coolers use from 40 to 200mm. So, to choose the right cooling fan, look at the system size in the manual, online or otherwise, you can measure it from hole to hole.

On the basis of that, you can consider the place where you would want to mount the fan. Vertically mounted fans are common for intake and exhaust. However, many modern cases also allow horizontal mounting as well. It causes a direct effect on the type of bearing you use.

Bearing Type

Coming to the bearing, it's a small piece(s) of metal that stays between the stationary frame of the fan and the spinning part. So, if you ever wondered why there was a rattling sound coming from the system, it was probably bearing pieces. These bearings are very important as it is the mechanism on which cooling fans spin on.

Types of Bearings:

Sleeve Bearings are affordable but they might cause noise. Possibly they can prematurely wear out if mounted horizontally.

Rifle bearings: They are probably the cheapest fluid dynamic bearings. Fit for most case fans. Also, they are the cheapest solution for long-term horizontal mounts.

Ball bearings: They are expensive, heavy-duty fan bearings suitable for tough environments.

Maglev bearings: These bearing provide a balance of power, security, and minimized noise. Best for high-performance environments.

The Application

Most of the computer cooling fans are designed for either of the two purposes: Airflow or static pressure. Air fans evacuate as much air as possible from one place to another place. They have a grille or light mesh which allows the air to move freely and easily. And on the other hand, you have static pressure cooling fans which are used to push the air out through obstacles such as CPU heatsink. For example, Fanuc cooling fans push the air through obstacles. Fanuc is among top brands for cooling fans and you can always search for Fanuc parts to get quality products.

In most of the PC builders, it is important to choose a fan with good quality focusing on long-term reliability.

Header Connection Types

Almost all the types of fans come in 3-pin or 4-pin varieties. That also means that the wire which connects the fan to the motherboard has either three prongs or four prongs as a connection point. The connectors on 3-pin models carry three types of signals: Power, ground, and a speed sensor. They speed up or slow down with the variation of DC current on the power pin. As a result of it, 3-pins fans often run at full speed or might be achieving low speeds because of undervolting. The fourth pin on 4-pin connectors allows Pulse Width Modulation(PWM). It adds another electronic signal that controls the fan speed. It is important to note that 3-pin fans would work in 4-pin motherland headers but it won't have a PWM feature.

Pro tip: Buy 12V fan for a desktop PC. Generally, 5V fans are for routers and other small computing devices.

RGB and Fan Controllers

RGB. They are a hot favorite of most people. Most of these RGB fans come with two plugs, one for power and another for RGB addressing. You can easily plug them both into relevant places on your motherboard. Controllers can simplify the process by the daisy chaining of multiple RGB fans. There are plenty of fans with non-controllable color lighting and PWM versions are easy to control by any of the basic internal fan controllers.

If all these details are overwhelming for you, or you just want to find an adequately cool PC with minimal hurdles it is important to focus on reputable brand names. Fanuc selling Fanuc parts and Fanuc cooling fans, Corsair, CryoRid, Fractal, etc. are among top brands. Also, don't forget to check the review score.

Saturday, May 18, 2019

Quick Tips to Maintain Shear Blades

Shear blades are one of the most important tools when it comes to the metal fabrication industry. Shearing, also known as die cutting is a process of cutting metal. The most common materials cut using shearing are in the form of a sheet or metal plates.

The process in which the cutting blades are straight is shearing and if there are curved blades then the process is known as shearing-type operations. There are four types of operations include blanking, piercing, roll slitting, and trimming. To improve the uptime of shear blades & to reduce the maintenance costs, it is important to keep those blades in shape.

Here are some tips to maintain your shear blade in top shape:


Understand the Root Cause

First of all, it is important for any fabricator to understand the functions, designs, and operation of each machine in the plant. One of the major causes of shear failure is the overloading on shear blades beyond its parameters. When you attempt to cut the metal beyond the recommended limits, it could possibly damage your machines as well as shear blades.

In order to maintain the shear blades, it is important to perform standard maintenance every day. Plus, using quality products is also a must. Amada shear blades are among the top market leaders known for its quality and low maintenance cost.

Inspections on Regular Intervals

Make sure to perform scheduled downtime maintenance in order to ensure the smooth operations of the machine. It is important to test all the functions used in day-to-day activities. Examine all the bearing for the emergency and safety functions of the machine as it is an important aspect.

Once done with the examination, documentation is important as well. With the help of it, you can reveal potential issues beforehand so that an immediate repair can take place by an expert. These documents will help in analyzing and prepare preventive measures in case of future emergency problems.

Set the Blade Properly

Before starting the process make sure that you fit the blade properly in the machine. When you set the shear blade properly it helps to extend the blade's life and machine efficiency. Therefore, make sure to set the proper clearance for the finer cut quality.

Additionally, it is important to clean the blades. If the clearance is high, metal would jam between the blade and machine. Hence, if the blade has no clearance, it would work smoothly. But if you set the clearance too loose, it might cause premature failure of the system.

Have a Basic Maintenance Plan

  1. As per your machine requirements, you can set a basic maintenance plan to ensure the smooth working of your blade.
  2. Make sure that the air system is working properly for cleaner air. It is important to maintain the regulators to help the pneumatic mechanism for proper functioning.
  3. Remember to check the lubrication before starting any operations. It is a must to keep the lubrication system clean and filtered.
  4. Whenever you wish to replace the parts, try searching "Amada Machine replacement parts", as they are the best in the market, in the search engine and you would find a number of them.
  5. Check machine clutch and brakes for thickness, lining, clearances, and signs of failure. In any case, they've worn out, replace them immediately to avoid costly repairs.
  6. Keep in mind that air leaks or failure of the counterbalance cylinder need your immediate attention. They ensure the proper operations of shear and its tooling.

If at any stage you feel that the shear blades need immediate assistance, you would find a number of Amada Machine replacement parts or Amada shear blades online for the same. Other than that, it is advisable to contact the experts quickly if you find something unusual in shear blades or any machine in general.

Source:- https://www.sooperarticles.com/business-articles/industrial-mechanical-articles/quick-tips-maintain-shear-blades-1723775.html

Friday, May 17, 2019

The Best Examples of Laser Cutting in Electronics Projects

Laser cutting is relatively cheaper than 3D printing and injection molding and for engineering projects, it is best to go with the cheaper option. In the field of electronics & engineering, you often require precise cuts to ensure the proper functioning of the prototypes or products. And Laser cutting is known for delivering such accurate results that too at cheaper rates. Moreover, you can also achieve a level of consistency if you are making the cut many times.

And just writing it won't give you a proper idea.

Let's see some of the electronics projects executed using a laser cutter and why did the inventors use laser cutting:

Nixie Clocks

RobG, a leading market leader adopted the laser technology to cut the clear acrylic to mount the nixie components and let all of that electronic design come together. For this use case, the design was easy to achieve with laser cut parts. There are only two simple pieces, a back and a front. No sides. Basically, this is a tabletop clock. Therefore, it does not need much coverage as regular electronics. This leads to fast cutting time which eventually is an important consideration while creating a product to sell.

Nightlights

Jakob Griffith created a set of simple plugin nightlights. He created everything, from the printed circuit design to the artwork attached in the acrylic, and the final assembly. He started the project keeping the laser cutting tech in mind rather the other way around. With the help of laser cutting, he was able to do all the detailed art-work in a few hours which might've taken days with 3D printing and other alternatives.

WITCH-E Emulator

Harwell WITCH is a renowned instrument to teach computing and a milestone in computing history. The WITCH-E project started by Dave Anders studies the engineering characters of the Harwell WITCH and try to extract its educational value. The team has a common motto to accumulate informative materials in a form of videos, writing, and tools such as WITCH-E replica and emulator.

So, when Dave was working on a prototype he used laser cutting in order to make numerous iterations of custom designs in an inexpensive way. It was important to have the proper layout as electronics were to be mounted on it.

Pro Tip: You can also start your very own small project in your basement or garage and for the success make sure you are using quality parts e.g. Mazak Parts, Prima Parts, etc.

Music Devices

Nathan Walker thought of building devices that makes it easy to perform and record music in a better way. After facing hurdles in the initial stage, he started looking for the available options. When he didn't find an appropriate option, he came with a solution. Which was a headless Linux box with a DAW which starts working as soon as you turn it on. You can plug in any type of keyboard with USB or traditional MIDI output. This way, you can instantly access great synths and piano sounds. In this, there are faders and knobs to control anything in DAW. Therefore, it is a kind of dynamic change. While installing the faders, knobs, and buttons, Nathan wanted a lot of fine details. He wanted them to fit perfectly through the holes. To make it possible, he chose the laser cutting rather than an injection mold.

Fri3D Biped Robot

This biped robot is one of the main projects at Fri3D camp located in Belgium. Based on Otto bipedal design, its face is the animal shaped badge given to attendees that perform double duty as the brains for the build. The version is laser cut out of MDF but imagine this cute badge in different acrylic colors.

MeArm Robotic Arm

The MeArm Robots Arm is considered as the world's most accessible learning tool when it comes to engineering with the smallest and coolest robot arm. This robot arm comes as a kit and its parts are given proper shapes using laser cutting. With the help of a screwdriver, you easily gather its scattered parts and build yourself a robotic arm. A great source of information for anyone new in the world of programming, electronics, robotics, and engineering.

You can also embark your engineering journey with a project using laser cutting technology and the ideas mentioned above. It's a cost-effective solution with cutting-edge results. You can try searching Mazak parts, Prima parts to find suitable components for your engineering project!

Wednesday, May 15, 2019

How to Achieve Burr Free Laser-Cutting

If you work at the laser cutting shop, you would notice that operators often offload the metal sheet of cut parts. After that, they would pick up the cut pieces from the nest for clean edges to make the sheets ready for the next operation.

Mostly right? But sometimes, you would notice that burrs on the surface still remains. It may vary from minor to major in size but with some precautions, you can reduce it. In order to discover the perfect setting, it is important for operators to know about the process in which a laser cutting beam, support gas, and workpiece get in contact to create perfect cut edges in the product.

Achieving a burr-free laser cutting is no longer a magic. It’s a strategy that revolves around the proper operation of laser parts which you need to understand thoroughly to resolve it. Let’s see how. 

Which Parameters to Check?

In general cases, the modern machine controls the laser beam elements. Like the beam profile and beam power. The beam focus consists of a particular grade, thickness based on optical focus.

To match the true focus position on the workpiece, automated technicians usually check a number of parameters including beam alignment, delivery system, centering the nozzle, focus position, etc.

If the operator observes a burr at the bottom of the cut part of the stainless-steel sheet, then firstly the operator needs to slow down the cutting speed of the laser beam. You can justify the reaction because in his perception, cutting speed is too high and the problem might have arisen from that. 

Once the operator has slowed down the cutting speed and the gas pressure, he would find a bigger burr. Therefore, the creation of burr depends on how the beam, material, and gas interact. And once you understand their interaction, you would understand the creation of burr.

The Burr Formation Process

While you work with the laser machine, there’s an intense amount of energy emerging out of the laser beam. That brings the metal’s temperature above its melting point. Hence, metal exceeds the melting temperature, during this, a strong force of gas removes the metal from the kerf. When you use nitrogen, the cutting procedure totally depends on the beam’s energy to melt the metal. But when you use oxygen gas to cut the carbon steel, it seems that hot metal interacts with oxygen that creates an exothermic reaction with added heat.

In such cases, they form the burrs due to the molten metal which solidifies before removing. That solid material would remain tougher at the bottom of the kerf, eventually forming a burr.

But what hardens the metal before you remove it?

Gas Kinetics

The operator should ideally alter efficiency, quality, and cost when nitrogen gas is concerned. Nitrogen can reach up to 50% of the variable costs. Therefore, it is important to control the consumption of such gas in laser cutting. Consider using Trumpf laser parts in order to maintain quality outputs. Make sure to select the smallest Trumpf laser nozzles to attain the desired quality of performance.

It is important to note that when it comes to supporting gas flow, nozzle size and diameter would make a big difference. When deciding, go for the smallest Trumpf laser nozzle size as they will get you a good quality of laser cutting without any burrs. Eventually, you can increase your flow rate with good molten metal separation without going high on pressure.

Slow is never better

The logic of “lower and smaller” diameter of nozzle and gas pressure is not applicable to the cutting speed. Hence, while you slow down the cutting speed, you would end up welcoming more heat than required in the kerf. Along with this the temperatures also rises and cause vaporization which disturbs the gas flow. As a result of it, this disturbance creates more burrs which make the quality even worst. You need Trumpf laser nozzles to ensure the proper interaction of cutting beam and gas which is the best way to avoid burrs.

Additionally, the operator can also save the material from burrs by increasing the cutting speed precisely. This increase in speed would minimize the heat and the ablation while restoring the gas flow dynamics to its appropriate state.

Carbon Steel Cutting by Assist Oxygen Gas

While shifting to oxygen cutting for carbon steel, the exothermic reaction needs to be at an accurate level because here, the oxygen purity level will play a crucial role. It is common that oxygen-cutting carbon steel benefits from a higher level of oxygen gas purity. We can increase the cutting speed by 30 to 40 percent if we work with 99.95 percent of oxygen global purity.

Concluding

Burr-free laser cutting is all about ensuring that the beam parameters and gas dynamics work in synchronization. Moreover, you also need to ensure that you are using superior quality laser parts like Trumpf laser parts for the best and burr-free laser cutting.

A detailed guide to eliminate the creation of burrs in laser cutting and achieve a stable process to produce smooth cutting edge results.

Monday, April 15, 2019

9 Proven & Useful Tips to Maintain Your Press Brakes

Press Brakes. The most important tool for any company running a production plant or factory. Even if you search for ‘Amada press brake for sale’ online there would be tons of options available there to choose from. They are expensive too, which means that they need intensive care and maintenance from your side to ensure its smooth functioning.
To help you maintain Press Brake machines for better-extended work life, we are bringing you some useful tips.
9 Proven & Useful Tips to Maintain Your Press Brakes
Wipe it out!
In general, it is advisable for all types of electronic machines and Amada machine replacement parts. Dust and dirt are among the worst enemies of these machines. Therefore, make it an essential step to regularly wipe down and clean your press brake machines. You can also use rust protectant to apply on the possible surfaces.
Lubricate Rails and Ball Screws
It is important that the back gauge is working and cleaned properly. To keep all the dust buddies away, lubrication is the key. Lubricate your rails and ball screws according to manufacturer’s schedule. Make sure that you wipe off all the excess lubrication after the application to make sure it does not collect debris and contaminants.
Don’t Forget Cooling Fans
They would be at the back of your press brake’s electrical cabinets. If I am not wrong, they are also known as vent filters. Dust usually blocks them. Therefore, make it a practice to remove them and clean out at least once a month or as needed. Make sure you keep the door closed except when you access it.
Clean the Lens Every day!
Lenses of your press brakes are the heart of these machines and Amada machine replacement parts. Even a small scratch on the lens can diffuse the laser. Therefore, make sure to use a clean, non-abrasive cloth to wipe off the dirt and clean the lens.
Pro tip: Keep a specific cloth set aside to clean the laser every morning before starting the machine to prevent any build-up on the lenses.
Cleanse the Surrounding Area
You don’t want the press brake machine getting dirty. Therefore, it is wise to practice cleanliness in the surrounding area as well. Make sure that you don’t have any junk lying around the machine area. It will help prevent further issues meanwhile increasing safety and productivity as well.
Tidy the Tooling
They collect dust easily. Make it a habit to change the wiping oil on a regular span. They make a huge difference. Make sure that you clean underneath your bottom die and wipe off the top part of the upper punch.
Seating the Press Brake Tooling
Whenever you load and unload your tooling, make sure that it is seating in a correct manner. Sometimes it becomes an issue that affects your press brake working. It is important that the upper tool is under a bit of tonnage to make sure it’s up where it’s needed. You also need to periodically check and verify the proper alignment of your tooling.
Inspect Your Machine
This should be a part of your regular maintenance cycle. Inspect and check your machine while cleaning to ensure if other parts are working fine. It helps you to monitor and solve the issues causing any unusual noises when you operate the machine. And when needed you can search for ‘Amada replacement parts online’ to buy the new ones. Check and tighten all your necessary bolts and connections on a monthly basis.
Park the Machine Right
At the end of the day when you are done with the working, park the machine in the bottom position. You can rest the beam down in the die or on blocks every night. With the cylinders and valves, it becomes much easier when the hydraulics don’t have to hold the ram up. Even if the press brake is brand new, pressure might bleed of holding this much weight.

Thursday, March 28, 2019

Types of Sheet Metal Laser Cutting You Need to Know

Businesses dealing in laser cutting machines are blooming nowadays. The trend of sheet metal laser cutting is engulfing the market with their working methodologies. You get several options for new types of machinery available in the market to enhance the final results of cutting.

Specifying the laser cutting method types, these are the available choices varied by the industry requirements:

  1. CO2 Sheet Metal Laser Cutting Machines
  2. Fiber Laser Cutters
  3. Direct Diode Laser or DDL
Let’s have an in-depth tour of all these methods to find out which one suits your standards and requirements.


1) CO2 Sheet Metal Laser Cutting Machines

This method is known as a traditional method. Many fabricators prefer to use this method, particularly for the +4mm sheet metal market. This type of method utilizes CO2 laser gas and electricity to create a laser beam. The fabricators then apply that onto the sheet metal. This method includes high-temperature operations which is one of the reasons behind the need for a higher capacity chiller unit.

However, due to the new introduction of new technologies in the sheet metal laser cutting and people are moving towards them. That brings me to the second type of laser cutting that is Fiber Laser Cutters.

Benefits:

Co2 Sheet metal laser cutting machines are widely used around the world and most of the fabricators are proficient using the same. Moreover, Co2 laser cutting machines are reliable and safe as they don’t come in direct contact with the materials causing next to no mechanical compression or stress.

2) Fiber Laser Cutters

Fiber laser cutters use optical fibers pumped with diodes to craft a solid-state laser cutting machines with no gas consumables. If you are working in this industry, then this type of cutters can produce precise results for you. When any fabricator is looking for a laser cutting machine, the main thing he is concerned about is efficiency. Fiber Precitec Laser Consumables provide speed, accuracy, and cost-saving results. One of the major things is that they contain a better focus capacity. Because of that, they can evaporate a material at pinpoint to make a smaller spot diameter, compared to CO2. This way you can make sure that the cut you produce is accurate and stable. This works well while you work with thin materials as well.

For instance, some of the Precitec laser consumables users use this technology to channel increased beam density and laser energy into the cut. With a shorter beam wavelength, you can produce a 90 percent shorter cut than a CO2 laser beam. It results in faster penetration of the material and the capacity to increase the operation by more than 30 percent.

They can also cut highly reflective machines such as brass, aluminum, copper. With a CO2 machine, there are chances of damage. Additionally, the fiber lasers are also well suited for other materials such as Hastelloy, Titanium, and Inconel.

Benefits:

According to a study, laser parts like LVD Strippit laser consumables provide manifold benefits. In terms of spending costs, fiber users can benefit from an 80 percent reduction in consumption of oscillator electrical power. And 100 percent reduction in laser gas consumption with a wall plug efficiency of 30 to 40 percent. They also reduce chiller unit electrical consumption to 80 percent.
In the fiber laser cutting, your maintenance costs would also gradually reduce because of lesser movements in its parts, lower consumption of heat, and longer diode life. It also reduces the sheet metal cutting machine maintenance because they do not contain bellows. Plus, there is no requirement for mirror alignment or replacement.

3) Direct Diode

The final method available for cutting sheet metal is a DDL technology. It is also known by the acronym DDL. In this method, the diodes are the key thing they use. Therefore, they eliminate the pumped fire system, used in fiber laser technology. Due to the elimination of the middle process, it makes it more efficient.

DDL is a reliable source method with enhanced beam quality. Machines such as Precitec laser consumables offer premium cutting performance which makes them ideal for users who need ultra-fast cutting and high-quality cutting results.

Benefits:

It enhances productivity by cutting thin material at a 20 percent faster rate. It is faster than fiber ones and it also works on thick materials with unsurpassed surface quality. The DDLs are capable of a wall plug efficiency level. That is of  40 to 50 percent more compared to 10% for a CO2 resonator. Also 15 to 20% for a disc resonator and 30-40% with a fiber resonator.

What is Your Choice?

The right choice of metal laser cutting is important to produce cutting-edge results which meet the requirements. Therefore, research, summarize your requirements, finalize the material and other aspects to choose the LVD Strippit laser consumables which are capable enough to produce fruitful results for your industry.