This year’s Austech was one of the largest Sydney shows ever, with over 80 exhibitors displaying the latest in metalworking technologies. Katherine Crichton looks at two machines demonstrated in Australia for the first time.
IN response to increasing global competition from low cost countries, Australian manufacturers are turning their attention to producing low volume, complex custom parts, adopting a lean manufacturing approach in order to reduce costs and increase profits.
In order to achieve reduced operator input, raw material stocks, set-up times, manual operations and costs while at the same time increasing production, users need fabricating systems that are flexible and reliable, with low maintenance costs.
Sheet metal equipment manufacturers are now producing systems which adhere to these principles and at this year’s Austech, a new generation of sheet metal machinery was on show, with many machines demonstrated in Australia for the first time.
One such exciting development was the RAS UpDownBend folding system located at the Sheetmetal Machinery stand, which according to Alain Ruckweid, sales engineering with RAS, was the main attraction.
“The folding system is new around the world. Never before has there been a machine than enables operators to fold parts without flipping,” Ruckweid told Manufacturers’ Monthly.
The machine is said to revolutionise the entire folding sequence by allowing the operator to finish one side completely before he turns the blank to the next side.
Automatically the folding beam changes direction and folds blanks up and down without a need for the operator to flip the blank. As the gauging system moves the part forward and positions it for each fold, the operator starts the semi-automatic folding sequence.
“The part is simply positioned against the gauging system and the new sheet support/gauging system automatically adjusts its size to the current folding position. When parts are small or narrow the table surface area decreases. On large sheets this surface unfolds to its maximum dimension. Thus the workpiece is constantly supported,” he said.
Ruckweid said one of the key characteristics of the machine is the simplified tool changes that ultimately lead to shorter changeover times.
“Users simply need to place the tools and switch it on. The machine clamps the upper beam and folding beam tools automatically, with versatile upper beam tool segments, max 150mm wide with side gripping pockets allowing for an easy tool change. The primarily stationary segmented lower beam tools are easily changed with a quick-lock system,” he said.
Other features of the system include a working length of 3200mm and high capacity folding which allows the machine to work with a maximum material thickness of 4mm (mild steel).
A new pivot point setting system adjusts the machine automatically for the material thickness and the desired bend radius — when folding upward, as well as downward. Thus the working plane always remains at the same height, even when the folding direction changes.
All these features do come at a price, but Ruckweid says the ROI is quickly gained as the folding system is effectively two machines in one and in most cases eliminates the need for two operators.
“You can bend parts in both directions without ever flipping the part and even large parts need only one operator to handle them. The next step will be to add further automation to this system but this machine is the future of sheet metal technology.”
Compact solutions
With much of the large quantity manufacturing disappearing from Australia, production runs are becoming smaller and shorter but as David Heggie, sales and service, GWB Machine Tools notes, customers still want automation and precision.
“We have noticed a trend towards more cost effective products. Customers don’t want to spend millions of dollars for all the bells and whistles when all they want is a machine which is compact and reliable,” Heggie told Manufacturers’ Monthly.
According to Heggie, one of the main attractions to the GWB stand was the LVD PPRM pressbrake which was demonstrated in Australia for the first time.
“We had a really positive response for this machine. What I think made it so attractive to visitors was its compact size. Most pressbrakes that are sold are on the bigger end whereas this machine has a working length of only 1250mm,” he said.
The machine has been designed for bending small to medium sized high precision parts and features a reluctance motor which is said to achieve higher bending speeds than most conventional hydraulic machines.
“At 35t, the press brake has a working speed of up to 25mm/sec and set-up is simplified with a 100mm throat allowing access to both ends of the ram and bed for tool loading. Other high production features include an open height of 385 mm and stroke of 185 mm,” Heggie explained.
“The machine’s high production capacity is attributed to a simple working principle. The press brake ram is supported by springs and uses two single-acting hydraulic cylinders. Each hydraulic cylinder is directly connected with a hydraulic pump driven by a servomotor.
“There are no switching valves in the hydraulic circuit and no lapsed time in the ram cycle because of mechanical movement of the valves.
“The result is higher production rates and greater machine reliability,” he said.
Heggie says the press brake consumes on average 30% less energy than conventional hydraulic press brakes as there are no mechanical components such as ball screws or gearboxes that will exhibit wear from friction and reduce accuracy.
GWB Machine Tools 07 3274 1762
Sheetmetal Machinery 03 9758 9377
