If you don’t have a lot of experience with metalworking or heavy machinery, you may not be very familiar with a turret punch. In this article, our experienced professionals at ACRA Machinery break down the ins and outs of a turret punch.

What is a turret punch?

A turret punch (also known as a turret press) is a type of press punch machine that is used to manufacture metal parts by punching shapes out of large metal sheets. The machine operates by using two turrets, with one placed above the machine (called a punch) and another below (called a die). Both the die and punch will move in sync with each other to punch the required shapes from the metal. Using a turret punch is great when it comes to making holes in metal sheets as the punch can be set to a variety of sizes and is perfect for mass production. Instead of a single punch, the machine uses a series of strokes that combine standard shapes like squares, circles, and hexagons to form the desired outcome.

Types of Turret Punches

There are two main types of turret punches:

• Manual turret punch
  • Before innovations in turret punch technology, manual turret punches were used. These are C frame presses that usually come with a rack-actuated ram. Using a manual turret punch requires great familiarity and experience as the machine does not come with sheet positioning or tool changing options. Hence, picking the correct tool from the turret for each operation is necessary.
• CNC turret press
  • CNC punching technology has made a tremendous breakthrough in turret punching productivity. This new technology allows reduced cycle time, increased machine speed and enormous simplifications in terms of how the machine works. A CNC turret press can have up to 60 press tools to pick from, making it more user-friendly. This also greatly reduces the training required before using the machine. The most common operations involving a CNC turret punch are basic punching, piercing sheet metals, nibbling, embossing, creating ribs or hinges and coining metals.

Do I need a turret punch?

It depends on what you are trying to achieve. If you want to cut many repetitive shapes in succession, a turret punch would work perfectly. However, if you are looking to cut more complex shapes, using a laser cutter might work better. Deciding which machine is best for you can sometimes be confusing so having a good understanding of the differences between a turret punch and laser cutter can be helpful.

Why should I use a turret punch?

There are many options for metal sheet manufacturing, each with its own set of unique advantages and disadvantages. Turret punches have many benefits and are typically chosen for the job if the desired outcome is high-speed production and a wide range of versatility. Turret punches are also a great fit if you’re looking to have flexibility in the scale of production as it offers more dynamic manufacturing than other methods. Anyone who needs a quick and economical way of punching holes through sheet metals should consider turret punches. The ability to contain multiple tools in one device also means that manufacturers can decrease expenses as custom punch tools for specialised jobs will not be required.

Is it dangerous and how can I avoid getting hurt?

Like all other machines, sufficient training is required before operating a turret punch. However, even with the necessary training, turret punch operators need to be fully aware of potential hazards such as contact or impact from moving parts, having hands or fingers trapped by the tool, excessive noise, slips and trips and contact or impact from unexpected machine movement. A few controls you can have in place to avoid these are defining “no-touch” areas on the machine when in operation, ensuring the machine is fully shut off when not in operation (especially when loading and unloading), wearing the necessary eye and ear protection and maintaining an overall up-to-date housekeeping procedure in your facility.

The machine itself can be dangerous if not handled properly but if you have all the right practices and procedures in place, operating a turret punch should be a breeze.

Turret Punching with ACRA Machinery

If you need some help with your current turret punch or you’re in the market for a new one, our highly trained personnel at ACRA Machinery can offer professional advice tailored to your specific needs. We stock a variety of new and used turret punch presses and can answer all your questions to help give your turret punch the longest possible operational life.

For more information on turret punching or any of our other sheet metal machines and services, get in touch with us by calling 03 9794 6674 or contact us via our online enquiry form.

In the sheet metal fabrication process, a turret punch press punches holes and shapes of different diameters quickly and efficiently. The machinery functions by pressing a punch into the metal material and pushing the excess metal into the die. The turret punch allows multiple tool sizes to be within one machine which can have a myriad of applications and advantages for your sheet metal manufacturing process. Here, the experts at ACRA Machinery have outlined some of the benefits of using a turret punch press so you can determine if it’s the right choice for your next sheet metal project.

1. Versatility

This soft tooling machinery has the capability of producing an infinite number of shapes and holes needed for your unique project. With interchangeable tool sizing and the ability to use multiple strokes quickly and efficiently, a turret punch can create circular holes, square holes, different shapes, perforations and forms. The variety of tooling configurations allows the machine to process complex parts with ease, and without having to stop the process to change parts due to the multiple tooling in one device.

2. Cost-effectiveness

Soft tooling is cheap to buy or replace as needed, which makes it the perfect choice for those one-off sheet metal projects or low to medium production runs. Turret punch machines also have high functioning speeds and extreme efficiency which causes less production time, less wasted materials and more money saved. Using the controller, the operator can quickly rotate the turret to select a different punching tool as needed, without needing to manually replace the tooling.

A turret punch also allows the assembly of larger projects to be tested with soft tooling. This allows businesses to avoid purchasing and constructing individualised stamping dies that could later need costly modification or redesign. This makes the turret punch machine a great choice for prototypes and projects with a more flexible design.

Turret punches and laser cutters have similar capabilities and versatility however, turret punch machines are perfect for cutting many repetitive shapes in a row and are often more efficient than laser cutters due to the faster stroke speed and higher number of hits per minute. Although they have a similar versatility to laser cutters, turret punch machines also include secondary operations like extruding, deburring, blanking, and tapping that a laser cutter cannot complete.

Punching also allows more of the galvanised coating to remain on the sheet metal’s edges which prevents rusting, although may not produce the same smooth quality that is preferred by some industries. This allows the turret punch to reduce production costs in comparison to laser cutting.

3. Technology advancements for increased safety

There are many recent innovations in turret punch technology that have made the use of the machine safer and components less time-consuming. This includes self-stripping punch tools and multifunctional combination tools that do not require the need to individually index the turret for each tool. The development of CNC programming has also increased the machine’s efficiency to achieve the maximum yield from the workpiece, reducing costs and wasted materials.

Our Durma Turret Punch features automated loading and unloading for increased efficiency and to reduce manual handling and the associated risks. The computer-aided design features allow it to be operated with supervision, further reducing the risk of punch, crush and squash points that can be exacerbated by repeated tool changing. With automated clamp positioning and tool lubrication, the CAD technology of the turret punch has reduced the number of steps in the operation process, leaving operators to simply follow the appropriate shear and punch machine safety procedures.

Interested in acquiring a turret punch press for your business?

ACRA Machinery stocks a variety of new and used turret punch presses for your workshop’s sheet metal fabrication needs. Our Durma Turret Punch offers faster punching speeds than mechanical presses with the added feature of automatic loading and unloading reducing manual labour time for your operators. With over 150 years of experience, our expert technicians are available for all your sheet metal machinery needs to help give your turret punch the best possible operational life.

If you’re looking to increase your workshop’s capabilities or if you have any questions regarding our sheet metal machinery repair or maintenance services, get in touch with us by calling 03 9794 6674 or contact us via our online enquiry form.

Laser cutting technology is widely used due to its incredible accuracy and ability to reduce workpiece contamination. The precision of laser cutters is changing sheet metal manufacturing. Although precise, laser cutters do require a certain level of maintenance including fume extraction or air filtration. As experts in laser cutting technology, the team at ACRA Machinery have detailed some of the different methods of air filtration for laser cutters so that you can find the right fume extractor for your workshop and avoid laser cutting mistakes.

Why is air filtration necessary?

While laser cutting technology is perfect for marking, engraving and cutting needs, they do emit smoke, dust, fumes, gas and debris from the metal cutting process. These fumes are unsafe for human health and so require an air filtration or fume extractor to avoid damaging the laser system or affecting the operator’s health. Laser fume extractors are important to ensure a safe workplace but there are a variety of factors that can impact which laser cutter fume extractor is right for your factory.

Factors to consider for your fume extraction needs

Before selecting the appropriate extraction method for your laser cutter, it is important to identify the contaminants that need to be extracted. Knowing the types of contaminants being released into the air from the removed materials or by the laser (in some cases) will determine the right filter and extraction units for your workplace.

To identify which by-products are released into the air by the sheet metal, read through the material safety data sheet or consult the manufacturer. Also consider if there are any assist gases such as nitrogen, oxygen or helium involved with the type of laser used in your sheet metal machinery. This will also need to be removed from the work environment.

Other factors could include the space available near the laser cutter and the workplace’s noise control needs. The type of airflow volume necessary also depends on whether the operator is simply marking or cutting the workpiece, so be sure to speak to trusted experts like ACRA Machinery when installing your laser cutting technology.

Non-filtered extraction

Non-filtered extractors prevent harmful fumes and respirable dust from entering the environment by capturing the emitted smells and particles from the laser cutter. However, this method does not remove the harmful particles from the captured air. These extractors can hold the fumes for safe removal at the end of the laser cutting process or the extractor can be fitted with a hose to directly vent the fumes outside of the workplace and into the atmosphere. It is the responsibility of the business to ensure that no harmful particles are exposed to the environment with this method.

Filtered extraction

If the fumes from your workpiece or laser cannot be safely vented into the environment, your laser cutter will need filtered extraction. A filtration system also draws the harmful fumes and air from the work area via ducting to prevent the air from entering the workplace atmosphere. Unlike exhaust blowers, filtered extractors don’t simply vent the particles and gas from the laser cutter into the environment. The fumes pass through filters that capture the airborne particles and release clean air, often at the opposite side to the intake.

Often filtered extractors will use charcoal filters that absorb chemicals and HEPA filters that catch metal and dust fumes, but there is a range of additional filtration options available to suit your needs. As part of maintaining your laser cutter, the pre-filter inner pads will need to be changed roughly once per week and HEPA filters will need to be replaced yearly at a minimum.

Filtered extractors can also have the benefit of being more portable than non-filtered extraction, which may have more permanently installed hosing for safe venting. Ultimately, the right fume extraction system will depend on how the laser cutter is used, the types of workpiece material and the site’s individual needs.

Looking to improve your laser cutting technology?

ACRA Machinery stocks a variety of laser cutting technology for your workshop including both new and used laser cutters. Our Durma laser cutters are all fitted with compact dust extraction filters for your operator’s safety and peace of mind. With over 150 years of experience, our expert technicians are available for all your sheet metal machinery needs to help give your laser cutter the best possible operational life.

If you’re looking to increase your workshop’s laser cutting capabilities or if you have any questions about effective air filtration, get in touch with us by calling 03 9794 6674 or contact us via our online enquiry form.

Reducing sheet metal wastage and offcuts is an important aspect in making your laser cutting machines more cost-efficient. While some wasted materials will be inevitable when cutting or bending metal, aiming to reduce the offcuts and scrap metal is at the forefront of every sheet metal manufacturer’s mind. At ACRA Machinery, we know how best to maximise the use of your offcuts and avoid scrap wastage when using your laser cutter. Read on for some quick ideas to reduce your business’ scrap metal waste.

Why is reducing wastage important?

Reducing metal waste when using a laser cutter has significant economic and environmental benefits. By planning your metal cutting techniques as efficiently as possible, you can control your manufacturing costs by maximising your material’s utilisation.

Reducing the unnecessary production of scrap metal saves your business money on material, reduces costs related to the transport of waste and reduces time spent cutting materials. It also minimises the amount of metal that heads to landfills and the emissions caused by unnecessary usage of your business’ sheet metal machines. After limiting your offcuts from your workpieces, consider investigating the process of recycling scrap metal for additional income.

1. Group pieces close together

Assess your current nesting of shapes when laser cutting. Is there a better method of arrangement that would get you a greater number of useful parts? If you are using manual nesting, be very intentional with your arrangement and group shapes together to fit the maximum number of useful pieces. For more complex or detailed projects, consider investing in automated nesting tools.

Automated nesting will combine shapes and quickly arrange designs into a pattern that allows less wastage of the workpiece, reducing your sheet metal costs. Preparing your arrangement and optimising your file layout from the beginning is also a very savvy and efficient approach for repeat orders.

2. Introduce shared cutting lines

A simple method of improving the use of your material is to always confirm that all shapes are sharing cutting lines when nesting. Rather than unnecessarily leaving space between shapes, arrange rectangular edges to share straight lines on the workpiece. This method prevents wasted material and shortens the machine’s cutting path, further reducing the usage time and running costs of the laser cutter.

Check that the laser cutting file has single cutting lines when the shapes are placed side-by-side and that you’ve accounted for how much the material the laser burns away. If your design features double lines or any overlap, your laser cutter will incorrectly cut twice.

3. Reduce curves and unnecessary components

Check for any curves or unnecessarily complex shapes during nesting to use the metal sheet as efficiently as possible. Curves and extreme details slow down the laser cutting process, so consider if there is a way to eliminate or replace these components. If the curved shapes are integral to the project, consider reducing the laser cutter’s traverse time by setting starting cuts at different positions for increased efficiency. This could be as simple as setting the first circle’s starting cut at the 3 o’clock position and setting the second circle’s starting cut at the 9 o’clock position for a shorter distance between cutting points. Remember, if the project contains many unavoidable curves and details, be sure to account for the increased process complexity in the client cost.

Keep trimmed material for future laser cutting projects

Not all scrap pieces are useless. Before simply dismissing your offcuts as wasted material, determine if there are pieces that can be reused to cut out more delicate parts. As laser cutting is highly detailed and accurate, there is little burring on the material, making the metal perfect for other projects. This could include smaller detailed work or test runs.  Although, keep in mind that many of these metals will have lost their tensile strength. Good quality storage will keep your offcuts fit for your next project by preventing damage or marks, so ensure that all scrap pieces are stored appropriately

Looking for a laser cutter?

ACRA Machinery stock a variety of laser cutters for your workshop including both new and used options. With over 150 years of experience, our expert technicians are available for all your sheet metal machinery needs to help give your laser cutter the best possible operational life.

If you’re looking to increase your workshop’s laser cutting capabilities, get in touch with us by calling 03 9794 6674 or contact us via our online enquiry form.

The press brake is one of the most versatile machines on the fabricating floor but, as with all heavy machinery, press brakes can be dangerous if used unsafely. Whether mechanic or hydraulic, press brakes form, punch or shear metals and other materials using high pressure which can injure workers during the operating or cleaning process, from heavy bruising to loss of limbs. At ACRA Machinery, we strive to improve worker safety in the sheet metal fabrication industry, so we’ve compiled some safety tips that can be implemented at your factory to avoid injuries unique to press brake operation.

1. Hearing loss or impairment

Press brakes are noisy during operation and may exceed safe noise intensity which can cause harm to those working near or operating the machinery. This long-term injury can be prevented by providing all workers on the factory floor with hearing protection such as earplugs or earmuffs. Regular assessments of noise levels should also occur to ensure the level of sound is safe. If following PPE guidelines in the metal workshop still does not reduce the sound to an appropriate decibel, consider installing a noise barrier or isolating your louder machines to protect your workers.

2. Cuts from sharp sheet metal

Handling sheet metal and scraps can also cause injuries unique to the workforce of sheet metal manufacturers. Sharp materials can cause cuts and lacerations to workers when performing actions like removing the workpiece from the press brake, but this risk can be reduced with safe handling procedures and protective gloves. All workers should be equipped with appropriate protective gear like hard hats, clothing that covers arms and legs, as debris and small shards of metal can enter the air during the fabrication process, causing cuts or blindness. Workpieces heat up a lot during the metalworking process, so to prevent skin injuries like cuts and burns bare skin must be covered at all times.

3. Muscle strains and back injuries

In the sheet metal sector, moving heavy pieces of sheet metal and machinery is a necessary part of the job and one of the many things to consider when designing your workshop. Strained necks and backs, and physical stress are serious risks in the industrial sector if workers lift, push or pull bulky material or machinery incorrectly or too frequently. There are also unique physical requirements in this sector such as exerting force to use tin snips on sheet metal.

To prevent muscle strains in your workplace, begin by reading WorkSafe Victoria’s Hazardous Manual Handling Compliance Code and ensure that workers have been trained in the proper lifting techniques for difficult-to-handle objects from the ground, low levels and above shoulder height. Workers should also disclose any physical limitations and know when they are required to find a second person or appropriate machinery.

Workplaces also have legal duties under the Occupational Health and Safety Act 2004 to provide and maintain a working environment that is safe and without health risks. Practices to avoid muscle strains include:

• Ensuring that there are appropriate storage facilities at the correct height.
• Wearing non-slip footwear with steel caps to prevent toe damage.
• Implementing non-slip mats across even work surfaces.
• Ensuring an appropriate workspace layout.
• Providing and encouraging mechanical aids such as trolleys.
• Ensuring there are enough employees and time for the task with job rotation where necessary.

4. Crushes and amputations

Crushing and amputations are arguably the scariest and the most severe press brake injuries. No workplace wants these injuries to occur to their workers and in Victoria, there is a range of safety systems and standards in place that machinery must comply with to prevent this injury. Permanently fixed guards are there to prevent workers from accessing any pinch or squash points. An unguarded press brake risks workers’ hands from becoming too close to moving parts or entering the hazardous trapping space.

There is a range of press brake guards available including two-hand controls which force the operator to maintain a safe distance during the sequence mode or a light curtain mounted close to the dies which stop the machine upon disruption. Physical perimeter guards that are permanently fixed or require tooling to be removed, particularly to prevent reaching the dies from the back, also help stop workers from becoming too close to the moving parts of the machinery and injuring themselves.

Outside of physical guards and engineering controls, there are also safety procedures in place to prevent a worker from accessing moving parts while the machine is operational.

• Slip mats should be in place to prevent accidents.
• The working area should be left clean and tidy to prevent tripping hazards.
• The operator should not be on their phone or otherwise distracted from the press brake.
• An operator should always be monitored by a highly trained supervisor.
• The press brake must never be left unattended while operational.
• Maintenance should be performed by a qualified professional.

When cleaning or repairing the press brake, lock out all power supplies, add chocks to prevent the ram from falling and isolate the controls to prevent accidents and entanglements with the machine. Remember to adequately train operators in all safety and harm minimisation procedures and ensure your press brake is regularly inspected and maintained to comply with all safety requirements.

Are you looking for a new or used press brake in Melbourne?

ACRA Machinery is a one-stop-shop for all your sheet metal machinery requirements including new and used press brakes from trusted brands. Browse our online catalogue or chat with one of our specialists to find the right bending machine for your sheet metal fabrication needs. We also offer on-site repair and maintenance services so you can keep your machines in prime condition.

To get in touch with our expert team, give us a call today on 03 9794 6675 or fill out our online contact form.