One of the most important resources on planet earth, metal has helped human civilisation advance in a way that no other species has ever been able to before. Although metal is ubiquitous in our everyday lives, it’s probably not something you think about all that often. This week, we delve into the secret life of metal with ten interesting facts.

1. The most abundant metal on Earth is iron, and it makes up most of the Earth’s core. The Earth’s crust on the other hand, is primarily aluminium.
2. Until the middle ages, there were only seven types of known metal including bronze, silver, lead, copper, mercury, iron and of course gold.
3. Brass is naturally antibacterial and that’s the reason why it is so commonly in public buildings for finishings like doorknobs and handrails.
4. The iconic Eiffel Tower is six inches taller during the summer months than it is during winter. This is because the iron and steel which the landmark is made of expands and contracts according to temperature.
5. If two pieces of uncoated metals touch, they permanently fuse together. On Earth, this doesn’t happen because the atmosphere puts a thin layer of oxidation between the metals, acting as a barrier.
6. The best metal for conducting electricity is silver, but it’s high cost means that in most commercial electrical products, copper is used instead
7. Structural steel played an integral role in the construction of the first sky scraper in 1883. The building constructed was the Home Insurance Building in Chicago and it was demolished 47 years later in 1931.
8. The word metal is a derivative of the Greek word ‘metallon’ meaning to quarry, mine or excavate.
9. 75% of the elements on the periodic table are metals. There are 118 known elements and 91 of them are metals. A number of the remaining 27 elements possess characteristics of metals and are referred to as semimetals or metalloids.
10. Mercury has the lowest melting point of all metals and is the only one which is in liquid form at ordinary room temperature. However, there are a number of other metals with a very low melting point. Gallium for example, can be melted in the palm of your hand.

 

Acra are well established sheet metal machinery suppliers with extensive industry experience and expertise. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

All metal fabrication companies are not made equally. Service, quality, and efficiency varies widely across the industry, so it’s important to be able to discern whether or not a particular company has the capability and professionalism required to get the job done. This week, we take a look at five key factors to consider when seeking out a sheet metal fabricator.

Capabilities

Firstly and most importantly, you need to determine whether or not the fabricator has experience with your type pf project. Most sheet metal manufacturers specialise in a particular area and the processes different companies in the industry use can be radically different. You need to find a company capable of working with the grade, gauge and type of metal your project requires. Some fabricators may agree to take the work on and simply outsource the work, which can mean a compromise on quality and an increase in cost. So make sure the fabricator you choose has the experience, skilled staff and production capacity to complete your project in house.

 

Experience

Practical hands on experience can make an enormous difference to product quality in the fabrication industry, so it’s important to choose a company with an established track record. Try to find a company capable of breaking down a project into detailed costs, can translate shop drawings into viable plans, certified workers and project managers with hands on experience.

 

Quality

Make inquiries into the quality control processes that the fabricator undertakes on each project. Also read up on the certifications the company holds so you understand what compliance regulations they adhere to.

 

Methodology

Ideally, a fabricator should have a methodology that is client focused and ensures the project is managed and tracked at every turn. A good company should be able to both track and manage even the most complex projects as part of their process control.

Customer Service

To reiterate, customer satisfaction is the single most important factor in any metal fabrication project and you need to find a company that entrenches customer service excellence as part of it’s business philosophy.

 

Acra are well established sheet metal machinery suppliers based in Melbourne. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

This week, we continue to look at the maintenance requirements of hydraulic press brake systems. This is the second and final part in our series about how you can extend the lifespan of your hydraulic press and minimise breakdowns through regular maintenance and vigilance.

 

Check the control wiring

Control wiring needs to be checked on an annual basis to ensure it’s in good condition and all of the connections are secure. Any loose wiring needs to be tied with wire ties or placed in wire ways, whilst spare or unused wires need to be capped off or removed. Finally, any dust or debris present needs to be cleaned away to prevent damage or degradation.

 

Tend to frayed hoses immediately

Tend to frayed hoses or incorrectly crimped fittings immediately as these can cause plumbing failures. To ensure they can withstand any kind of system pressure, fittings need to be crimped by an authorised facility, and hoses should always be positioned in a way that ensures they cannot touch one another.

 

Change filters regularly

Oil sampling should be done at least once a year to determine whether or not your filters need changing. Sampling will be able to give you an indication of the kinds f particles present in the oil, whether there is water present, and the lubricity. Sampling will also let you know whether the right micron level of filtration is being employed.

Prioritise clean oil

Dirty oil and low oil levels can limit the lifespan of your hydraulic press, so it’s important to ensure the oil is not compromised by heat or dirt.

 

Optimise oil temperature

48˚ is the ideal temperature for oil in a hydraulic press, and the the cooling mechanisms for this part of the system need to be properly cared for to ensure they are able to maintain this number. To do this, the radiator needs to either regularly cleaned to remove dirt and debris that inhibits airflow, or by attaching a filter to the heat exchanger.

Keep the temperature below 65˚

Generally speaking, a hydraulic press should run relatively cool compared with other machinery, ideally somewhere between 48˚ and 60˚.

 

ACRA stocks a number of different new and used press brake technologies including hydraulic presses. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

 

Probably the most popular type of press brake technology, hydraulic presses are a great solution for manufacturers seeking accuracy and control in high tonnage operations. To get the most out of these machines however, you do need to be vigilant and perform regular maintenance checks. This week, we run through five essential maintenance tasks you should perform in order to keep your hydraulic press in good working order.

 

Perform regular leak checks

Only a damaged hydraulic press leaks. If you notice a leak, check the ram of the press, O ring seals, valve seats, hose end fittings, and hydraulic lines immediately to identify the source of the leak. Lubrication issues are a common cause of leakage, so it’s important to consult your operation manual and apply the correct kind of lubrication wherever necessary.

 

Do a daily check

You should perform a daily check for oil leaks, oil level, loose bolts, guided platens and press ram lubrication (it should be light), oil temperature, and general cleanliness as well as the automatic shutdown function when the beam is broken.

Ensure pressure builds quickly

A hydraulic press in good working condition takes no more than 1.5 seconds to reach the maximum required pressure. If the pressure build-up takes more than two or three seconds, this could indicate a pump problem, that the relief valve is working too slowly, or that the press motor is not producing enough revolutions per minute for pressure to build up. Dirt or debris in the line, or the valve being open too wide are both common causes of compromised valve function.

 

Keep an eye on valve shifts

When working properly, valve shifts should be smooth and silent. Any banging noises which occur during speed changes could be an indication that something is not working as it should be, and needs to be investigated as soon as possible.

Count the strokes

Valve coils typically have a lifespan of 3 million strokes, whilst relays have a life cycle of 1 million strokes. Keeping an eye on these numbers helps you anticipate when the coils need replacing, so you can do it before they fail and reduce overall downtime. Use an hour meter or no resettable cycle counter to establish accurate lifecycle times and develop a maintenance schedule.

 

ACRA are a reputable stockist of new and used press brake technology. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

As a manufacturer, the prospect of having to replace your machinery is never a pleasant one, and probably something you’ll want to put off. However, at some point, you need to seriously consider whether or not the equipment you currently have meets the operational requirements of your business. This week, we run through five clear signs it’s time to invest in some new machinery.

It doesn’t fit in with your current system

A machine can only be an asset to your business if it is able to be properly integrated into your production system. A machine that runs too fast, too slow, or on a completely different operating system to the other elements in your production line makes it impossible to get the most out of your system. After all, a chain is only as strong as it’s weakest link.

It slows the workflow

By extension, if a machine can’t work in tandem with others in the system to achieve a consistent workflow, it needs to be replaced.

There is safer technology on the market

Whilst it’s not always economically viable or sensible to always buy the newest, flashiest model on the market, in the manufacturing world operational health and safety considerations are paramount, so if there is a new technology on the market that reduces the workplace hazards faced by your employees, it’s well worth investing in.

 

It has suffered several breakdowns over the past year

As a machine is coming to the end of it’s working life, the various working parts will begin to wear out and break down. If you’ve noticed an increase in the number of breakdowns or part replacements in the last twelve months, then it’s probably time to start thinking about upgrading.

 

It has escalating operating and maintenance costs

By the same token, if the operational costs of the machinery such as it’s energy consumption and maintenance requirements increase, then a new machine may be a more economically viable option.

 

ACRA offer an extensive range of new and used sheet metal machinery for sale. To learn more about our stock and services, please don’t hesitate to get in touch with our friendly team by calling 03 9794 6675.

This week, we continue navigating the complex process of choosing the right die for your press brakes. Here are two more important formulas you can use to inform your tooling selection for air bending.

Select a die opening half the working value of the die

To ensure your die are used at an optimal rate, it’s best to use it at half of the maximum working rate. This can be determined by finding a die opening where the bend occurs halfway down the die face which you can find through the formula:

(outside bend radius x0.7071) x factor

 

Calculating the outside radius can be done by adding the inside ben radius you need to the material thickness. The factor in the formula refers to a multiplier around 4.0 inches which will give you a geometrically perfect bend, but does not allow for spring back, so you’ll need to increase the multiplier slightly to around 4.85 for materials with a thickness less than 0.125 in. and 5.85 in for materials between 0.125 and 0.250 in. If you have a material thicker than 0.250inches, the calculation changes. Using this formula will keep the relationships consistent regardless of radius size and material thickness ratios.

Use [(575 x material thickness² )/die opening] x material factor to determine tonnage per foot

This is based of a 60,000 PSI tensile AISI 1035, but the factor for a specific material can be obtained through a comparison of tensile strength. This can be done by dividing the tensile strength of your material by 60,000 and then insert the resulting number into the ‘material factor’ part of the equation. The length of the bend also needs to be looked at to ensure you’re within the tonnage limits of your press brake.

 

If formulas aren’t your thing, it is possible to use software

Automated calculation software is increasingly common within the press brake tooling industry, and there are a number of quality software packages available from brands such as SomaBEND and Cincinnati Incorporated.

 

ACRA are proud to supply operators in the sheet metal industry with quality new and used machinery. Our range encompasses both press brakes and tooling dies. We recently received a number of quality new press brake tooling dies from our Italian supplier, Euram Tooling, so now is the perfect time to invest and expand you tooling library. To learn more about our capabilities, please don’t hesitate to get in touch by calling (03) 9794 6675.

 

 

 

Achieving the correct radius requires the right tooling press brake, and determining this can be a tricky process given the number of factors which come into play. This week, we run through a few key tips you should use to inform your tooling selection procedure for air bending.

When it comes to cold rolled steel, follow the 8X rule

Typically, it’s always best to choose a die opening width which is eight times the thickness of the material you are working with. This tends to produce the best working results, helps to ease forming, and ensure bend angle stability all whilst working within tonnage requirements.

 

The 20% is useful for calculating bend reductions in all material types

It’s useful for defining the inside radius in air bending over a die and calculating bend deductions, however, it does not take into account spring back or tonnage limits and is therefore not suitable for developing a die opening.

If the bend radius is larger than the 1-to-1 ratio through the 20% rule, don’t panic

One you’re found the right die width and calculated the bend radius using the 20% rule, you’ll probably find that the actual radius will be slightly higher than the material thickness. Provided the difference is small, this isn’t a problem as short of custom tooling or stamping, it’s almost impossible to achieve a precise 1-to-1 ratio.

The inside bend radius should never be less than the minimum sharp bend radius

If this rule isn’t followed, the bend turns sharp, the punch will dig a ditch into the material. When this happens, it becomes impossible to physically achieve the inside bend unless you resort to stamping or bottoming. You need to aim for a one to one material thickness ratio and this can be easily achieved provided your press brake can handle the tonnage.

 

ACRA are established sheet metal fabrication industry suppliers specializing in quality new and used machinery including press brake tooling and dies. We currently have an extensive range of quality press brake tooling dies from our Italian supplier, so now is the perfect time to expand your tooling library by investing in some new dies. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling (03) 9794 6675.