One of the most important parts of the press brake process is choosing the right tools. But what are the best tools for the job? And how do you best assess tool capability, such as the kind of loads they can withstand? With the following advice, we’ll go over how to make sure the tools of your choice can manage the tonnage required.

Straight Punch Tonnage

 

Estimating the maximum allowable tonnage for a given tool depends on material type, tool hardness and tool geometry. A standard straight press brake punch will endure far more tonnage for every meter than what the press brake itself can withstand. As a rule of thumb regarding how much a press brake tool can withstand, never apply full machine tonnage over a length less than 60 percent of the distance between side frames.

 

Gooseneck Punch and V-die Tonnage

 

There are variations when it comes to gooseneck punch tools, but standard throat depths begin at about 20 percent of total tool width past the centre, leaving about 30 percent of the tool to take the tonnage at the bend. With any increase in throat depth, there is decreased tool capacity for tonnage. As for V-die tools, the maximum tonnage is 30 tons per foot, with consideration to the maximum load.

 

When in doubt, make sure to use the above advice as a guideline for the estimating the tonnage capabilities of press brake tooling equipment. For personal safety, and to ensure longevity of the tool, ask the manufacturer to explain the deflection factor for the tooling length and tonnage application of the particular equipment, and substitute the specified values in the formula.

 

ACRA Machinery have a full team on site, offering services for maintenance, machinery repair and servicing requirements. ACRA’s press brake tooling is built upon the values of precision and efficiency, and they’re sure to offer you the best tools for what you need. Get in touch today by calling 03 9794 6675.

 

 

This week, we look at some of the latest innovations in turret punch technology that is enabling sheet metal manufacturing fabricators to provide better delivery and higher quality.

Combination tools

A revelation in terms of turret punch productivity, suppliers are beginning to combine different tools in a single machine. Not only is this more cost effective and takes up less space, it also means there is no need to individually index the turret for each tool.

 

Self-stripping

Traditionally a ram was used to both actuate the punch press and pull it away from the metal. Although this was fine from a quality perspective, it increased production time as well as wear on the ram. The introduction of self-stripping punch tools means that the ram only needs to move in one direction (when actuating the punch) as an internal spring is used to retract the punch automatically.

 

CNC punching technology

CNC punching technology has made an enormous difference in terms of turret punch productivity. The latest CNC innovations have been focused on reducing cycle time and speeding up the machinery but the technology has also been used to simplify sheet metal manufacturing through user friendly programming systems which reduce the demand for skilled workers and reduce the number of steps in the operation process.

Stroke setting

New tool designs make compensating a punch after it has been re-sharpened a much less time consuming job. Instead of using shims in the punch guide assembly to set the optimum length, the new push button adjusting system eliminates the need for shims and instead guides tool assembly in increments of 0.0001 inch. The push button setup speeds up the process substantially and also ensures consistency.

 

Stripper plate setting

The push button system has also used to hold the stripper plate in the guide. Instead of using screws to fasten it in place, a push button locking system is used to keep it secure. This eliminated the need for installation tools and can reduce setup times by as much as 15 minutes per tool.

 

Acra stocks a quality range of new and used turret punch machinery. To learn more about our product range of the additional maintenance services we can provide to Melbourne sheet metal manufacturers, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

In the sheet metal fabrication industry, bandsaw blades are one of the most widely used tools, but their maintenance needs are often overlooked as unlike more complex technologies, they tend to remain relatively functional until the point of breakdown. Establishing a proper maintenance schedule for your bandsaw blade not only results in increased uptime (and therefore productivity), it can also reduce overall maintenance costs in the long run. This week, we examine the key steps involved in proper bandsaw blade maintenance.

Understand how your bandsaw works

Different bandsaws are designed to cut different thicknesses and widths of metal, so it’s important to understand what the machine you have is good at and what it’s limits are before you begin working with it. Whilst this advice might sound obvious, the most common reasons bandsaws fail is because they are overloaded beyond their parameters.

Follow the instructions

Make sure you perform the standard maintenance and adjustments every day in accordance with the manufacturer’s guidelines. Regular lubrication and fluids are also important to use to avoid damage.

Inspect and document

Although it might seem like unnecessary downtime if your machine is performing well, scheduled maintenance should be prioritised. All functions of the bandsaw should be tested, bearings checked for wear, and safety functions examined. The outcome of these inspections should then be documented. Documentation allows you to analyse the reports to identify patterns and emerging problems, so you can get them fixed before they cause downtime.

Make sure the blade clearance is properly set

Setting the proper clearance not only ensures a high cut quality, it also helps to protect the blade from damage and extend the life of the bandsaw. If the clearance is too low, the blade will break, if it is too loose, it will cause more wear and tear than is necessary and if it is set too high, the cut will be compromised.

If your bandsaw needs repairing, don’t wait

If you notice unusual wear or your bandsaw blade needs adjusting, call in an expert to fix it as soon as possible. Minor problems can quickly become expensive disasters if ignored.

 

ACRA stock a range of quality new and used bandsaws in Melbourne. To learn more about our range and the additional maintenance services we offer, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

Hydraulics are one of the most commonly utilised technologies in sheet metal machinery. This week, we thought we’d take a look at this simple, yet highly effective technology through ten interesting facts.

1. Hydraulic systems don’t actually create energy, they simply convert existing energy into another form.
2. There are three types of hydraulic energy. These are kinetic energy (produced by the moving liquid), the heat energy (produced through flow resistance), and there is also the pressure energy.
3. Hydraulic systems don’t ‘pull’ the liquid, it is pushed through by air pressure.
4. Liquid flow must be unrestricted for a hydraulic system to work. If the flow is blocked or has an alternate route, the pressure in the hydraulics will drop and it is this pressure that produces the energy.
5. Energy used by the hydraulic system is converted not just in the operation of the system but also lost as heat produced by flow resistance.
6. There are two different types of hydraulic systems: open centre systems which have varied pressure and a constant flow, and closed centre systems which have a varied flow and constant pressure.
7. In the sheet metal manufacturing industry, hydrostatics is what is used to produce power. This involves using fluids at low speeds but high pressure. The other type of hydraulics is hydrodynamics which uses fluids at high speeds but lower pressure. A propeller is an example of a system which uses hydrodynamics.
8. Incredibly powerful hydraulics are what is used to power NASA’s space shuttles. The pumps NASA uses have an RPM of 3600, each potentially holding 3050 PSI.
9. The term hydraulics is derived from the Greek work for water which is hydros
10. The principles of hydraulics where established as far back as the 17^th The first hydraulic presses were commonly used to pump beer up from the cellars up to the bar tap in pubs.

 

Acra stock an extensive range of new and used sheet metal machinery including guillotines. To learn more about our product range and capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

This week we give you a run down on one of the most popular types of cutting technologies used in the sheet metal manufacturing industry – the humble plasma cutter.

What is it?

Plasma technology uses pressurised gas (usually nitrogen, argon or oxygen) which is sent down a small nozzle containing a negatively charged electrode. An electrical circuit is created when the tip of the nozzle comes into contact with a metal workpiece, creating a spark which heats the gas to the point that it becomes a stream of plasma.

How does it work?

When the super-heated plasma comes into contact with metal, it reduces the metal to molten slag which then falls away, creating a cut. The plasma stream is controlled by shielding gas, released by other channels in the nozzle. These can be altered to vary the thickness of the cut as well as protect against oxidisation.

Which industries are plasma cutters best suited to?

Plasma cutting technology has a wide range applications from industrial scale construction such as transport fabrication (vehicles, ships and planes etc.)  to small business (i.e. locksmiths).

What are the advantages?

Perhaps the biggest advantages of plasma cutting technology is its affordability when compared with more advanced cutting technologies. As it has been used in the sheet metal manufacturing industry since the 1980s, plasma technology is much more affordable when compared to newer innovations such as laser cutting but is able to remain competitive from an operational standpoint as it has been integrated with modern technologies such as CNC. Other advantages of plasma technology include it’s fast production speed, adaptability, versatility, low cost operation and good automation.

What are the disadvantages?

There are only two key disadvantages of plasma cutting technology. The first is a much wider kerf than laser and water jet technologies. The second is restrictions on dry cutting of up to 160 mm for dry cutting and 120 mm for cutting under water.

 

Acra sell high quality plasma cutter machinery in both new and used condition. To learn more about our range, or to chat with one of our knowledgeable consultants about the best technology for your needs, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

 

The level of manufacturing across Australian industries has rapidly declined in recent years, with many manufacturing plants closing down and outsourcing their requirements to overseas factories. In order to maintain a successful manufacturing business in Australia, business owners and managers should focus on a few key factors, including innovation, productivity, investment, and funding, designed to keep them competitive in a gloabalised market.

Innovation

In order for local manufacturing businesses to remain viable, they need to put a strong focus on innovation. Innovation is often applied to issues like development and new technologies, however it also comes in handy for problem solving and business transformation. Examples of innovation specific to the manufacturing industry include refining supply and distribution channels, or exploring more efficient and cost effective ones­, improving processes, working to provide a better customer experience, finding ways to incorporate more environmentally friendly practices and technology, and establishing exciting new business offerings and connections.

Productivity

Boosting productivity in the manufacturing industry isn’t just about cost cutting – it’s also about increasing revenue. The best way to boost productivity is to develop a deep understanding of your industry and your customer base, and to discover ways to expand your services to meet market expectations. Making your internal processes more efficient and embracing new production technologies is a great way to further boost productivity.

Strategic investment

All successful businesses require investment in order to grow and survive industry pressures. One of the best investments a manufacturing business can make is in the workforce, hiring people with the skills and knowledge needed to stay ahead of worldwide trends. In manufacturing, your workforce is your biggest asset, so it pays to keep them happy and work to improve and expand their skills.

Funding

Of course, even when following all of the above, it’s unrealistic to expect manufacturing businesses to continuously turn over huge profits, so backup funding is needed to support the business when short-term dips in cash flow occur.

Focusing on these key areas will help your manufacturing business not only survive, but thrive in a globalised market, where quality at skill is more valuable than ever before. If you run a sheet metal fabrication business, look no further than ACRA for the highest quality sheet metal machinery.