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.

On this blog, we often talk about the ways investing in advanced sheet metal manufacturing technology can help improve productivity. However, machinery is only half of the equation in the manufacturing industry and the human element is often overlooked as working on employee productivity tends to be a lot more complex than simply upgrading your machinery. Despite this, if you can get it right, improved worker productivity can have a significant impact on your bottom line and also help improve both  job satisfaction and morale. This week, we look at some of the ways sheet metal manufacturers can improve worker productivity.

Examine existing workflow

The first step in improving productivity is to identify inefficiencies in the workflow. To do this, you need to evaluate the processes, technology and of course the people required to produce your product. When focusing on employee productivity, look closely at things like procedures, communication tools and channels and resources to see if there is room for improvement. From there, value mapping can be an effective way to identify and monitor process improvement to see the impact on the workflow.

Anti-fatigue matting

Anti-fatigue matting can play an important role in boosting productivity as it enables workers to perform for long stretches of time without any pain. Anti-fatigue matting improves posture and blood circulation, reduces body aches, helps preserve energy levels and helps workers feel physically comfortable and supported throughout the day.

Invest in employee education

In an industry that is constantly evolving both in terms of technology and procedural processes, there are plenty of opportunities for employees to advance their professional skillset which ultimately adds value to your business and ensures you remain up to date with the latest specialist technologies.

Foster a team environment

Although it’s made up of separate stations, a manufacturing floor is most productive when everyone is united and working towards the same goal and lag, waste and conflict is kept to a minimum. Creating a co-operative environment requires a dual approach of running regular team building exercises and working with employees individually to ensure they feel comfortable and see themselves as part of the team.

 

ACRA are proud to provide Melbourne sheet metal manufacturers with a comprehensive range of quality new and used sheet metal machinery and accessories including anti fatigue matting. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

Endlessly variable and hardworking, ironworker machinery simplifies many difficult metal fabrication tasks. This week, we look at how you can improve the productivity of this already invaluable piece of machinery.

Ironworkers have a punch, but don’t throw away your drill

Ironworkers tend to be limited in the hole sizes they can punch relative to the thickness of the material and cannot be used to punch a hole smaller in diameter than the material thickness.

More is better when it comes to throat depth

Throat depth should be deep enough for most of your work and be able to punch your largest part. Remember, you can’t add it later and if there is a special job, a drill can do the work instead.

Think carefully about the ironworker table

If you plan to use your ironworker for pipe notching or bending, it’s important to choose a table where the die holder is attached in a user-friendly way. Die holders can be attached with T slots, drilled holes, or tapped so it’s important to closely inspect before investing.

Die holder positioning is also important

If you need to punch close to the web, get a die holder where the die is near the edge of the holder rather than in the centre, as this can inhibit punching ability.

Different types of angle iron shear have different pros and cons

The slug-type angle iron shear is the best choice for those seeking a good cut quality, but it does cause some material loss and shimming. It also requires blade changes. If you need to cut a large piece of iron and want to avoid wasting materials however, the cropoff shear is the best choice, although it produces a lower cut quality.

The flat-bar shear is great for fabricating base plates, but quality varies

Different ironworkers offer different quality levels at this station and the rake angle in particular, can have a significant impact on the resulting cut quality. Broadly speaking, the higher the rake angle, the more distortion the drop piece has causing the material to roll or bow.

 

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

 

In the sheet metal manufacturing industry, laser cutting remains the gold standard in terms of speed and precision but did you know this futuristic technology was first theorised about over 100 years ago? This week we uncover 10 surprising facts about the history of laser cutting technology.

 

1. The relationship between energy and the frequency of radiation was first deduced by physicist Max Planck in 1900 who said energy could only be emitted and absorbed in chunks.

 

2. This theory was extended by none other than Albert Einstein in 1905 with his paper on the photoelectric effect. In 1917 Einstein presented his theory on stimulated emission, the process which makes lasers possible.

 

3. However, it would be 40 years before scientists would be able to prove Einstein’s theory in the lab. This was done in 1954 by Charles Hard Townes with the help of Herbert J, Zeiger and James P. Gordon.

 

4. Originally the strength of a laser was measured in ‘gillettes’ which refers to the number of razor blades a laser beam can cut through. Today, the strongest laser is as powerful as a hydrogen bomb.

 

5. Laser is an acronym which stands for Light Amplification By Stimulated Emission of Radiation. The term was coined by Gordon Gould in 1959.

 

6. Ruby laser technology was first used in a cutting context to drill holes in diamond dies in 1965.

 

7. In 1963 Kumar Patel developed the first Carbon Dioxide laser, which was more powerful and less expensive than the ruby laser previously used. A CO2 laser was the first to be used as for cutting metal in 1967 when it was used alongside oxygen jet cutting to cut through a 1mm thick sheet of steel.

 

8. The Being Company was the first to use laser cutting technology in a manufacturing context in 1970, it invented multi-beam laser cutting technology and used it to cut through ‘hard’ materials such as titanium.

 

9. 3D laser cutting was pioneered in 1979 and employed a 5 axes rotation system.

 

10. Laser cutting is renowned for its accuracy and indeed laser measuring is accurate to just over a nanometre (a billionth of a metre).

 

Acra stock a top of the range laser cutter from leading sheet metal machinery manufacturer Durma. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.