Wednesday, October 29, 2014

Modular Press using Multiple Punch Stations

The Modular Press using Multiple Punch Station product line by Vortool Manufacturing Ltd. contain a number of individual (portable) presses that are linked together and activated as one.

• For generic or budget oriented projects C Frame Presses are the most suitable.

• Other models may be used as well as custom solutions that are designed for the specific need of the process.

• Modular presses are excellent to process aluminum extrusions with great lengths and multiple holes, slots, etc. to be punched at once at the full length of the extrusion.

• The process time is minimal, compared to conventional methods where individual holes had to be drilled or punched one at a time. The quality is more predictable and repeatable.

• Multi axis power unit mounts are available to work horizontally or in an angle within the same machine.

• Drilling units can be also used to work along with the cylinders.

• Extrusion positioning and clamping can be automated. The function can be monitored by a PLC to ensure trouble free operation and keep the required quality under control.

• Safety devices may be installed, depending of your company or government requirements.

Friday, October 17, 2014

Metal Stamping

Metal stamping production is to produce low or high volume sheet metal parts. Production stamping is performed to cut, pierce, form, punch etc. usually in one operation. Materials could be any type of steel or material that is available in sheet format, foils as thin as .001” or to plate stock with thickness of up to ½” .

Metal stamping presses up to 500 tons for medical, lighting, electrical, automotive and construction industries. Stamping processes that we offer run from coining for finely detailed features, to deep drawn stamping, to progressive die for complex components.

Metal Stamping Materials
• Stainless Steel
• Hot Rolled Steel
• Cold Rolled Steel
• Aluminum
• Copper
• Bronze
• Titanium
• Foil

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Sunday, October 12, 2014

Non marking close space U shape bend with ready bender

Ready Bender - Non Marking Double Bend Part

Non Marking Close Space U Shape Bend with Ready Bender

Ready benders can replace any wipe bending method. The rotary motion is transferred from the press’ vertical motion and allows over bend past 90 degree to compensate material spring back.

This non marking method holds consistent angle tolerances and suitable for high volume production running at 250 spm. Other advantages include reduced tonnage requirements by 50 to 80%. In tooling, adjustments make it superior to wipe tooling. Tool trials and tweaking time is eliminated to a minimum, saving valuable set up time.

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Ball Bearing Guided High Precision Progressive Tool for High Speed Automated Production

The picture shows the bottom die set and 
some of its components are being inspected,
aligned and assembled.

Ball Bearing Guided High Precision Progressive Tool for High Speed Automated Production

Stamped metal parts usually require more than one operation in one. This tool produces a high volume mounting bracket that pierces holes, blanks out a shape by cutting the strip into separate parts and finally folds the part into an L shape. At each hit a final product falls off at the end of the tool. It is made for a high production automated punch press using coil and an air feeder for continuous operation.

The design consists all the necessary features that any stamping tool should have from ease of use through high accuracy to reliable operation for a long time. It includes strip feed and guide, stripping, slug separation, and feeder actuation. As an option the tool can be used as a manually operated tool without the air feeder using strips instead of coil.

The cutting components are designed to be made of hardened tool steel that ensures the long usability. Choosing the right alloy for the application and the proper design of the tool can greatly effect the life of the tool. As a result it can operate trouble free for longer, saving on maintenance. It can also reduce or eliminate downtime and minimize costs that are associated with the value of the final product.

The tool was designed using SolidWorks. Shop drawings, and files generated from the models are seamlessly fit into any machine shop or tool room's profile.

Tool and Die Design Advance Documentation with QR Code

Tool and Die Design Advanced Documentation
(Please ask for a Quotation)
• QR Codes: The VorTool QR codes contain valuable information for manufacturing purposes. The tool room or machine shop may have additional information that could possibly be put on a CAD drawing. The web based pages include images to fully explain how and what is intended to be done, and your input may also be included in the pages.
The QR codes if any, are printed on the actual shop drawings and can be accessed by using e.g. a smart phone with a QR reader. It is a visual and verbal extension of the CAD drawing or its part and or the assemblies.
The sample part drawing has many different holes that the CNC programmer will have difficulties to identify from the drawing. The additional web page has images with colour coded holes to visually identify all holes. The additional information possibilities are endless and can generally answer questions that the machinists are generally looking for.

Features on drawings, such as holes could be confusing for the programmer using MasterCAM or similar software to generate paths and then NC files to CNC machine the parts. On this example, there is a plate with a number of different holes, like dowel holes, tapped and counter bored holes, etc.
To keep the drawing clutter free yet provide enough information is not always possible. The larger the work piece and or more holes to be processed, mistakes can be easily made. The 3D model’s holes were assigned with different colours, then a web page was created with a color code chart to Identify the holes.
A QR code was generated from the web page and was placed on the drawing. The machinist can scan the code with a smart phone and have an instant answer of the ongoing questions about the type of holes to be made. You may not think it is a big deal but if you know that e.g. MasterCam does not recognize the tapped holes as a feature, than you will find this visual aid invaluable. The designer can have additional images, notes, etc. attached to the web page or pages to have instructions available at hand at all times.
To take a test drive and see how it works, scan the code with a QR code reader (free app for your phone) or download the print and then scan it. Once scanned, the web page automatically opens to view.

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