FOCUS ON METALWORKING
It does not sound much, but it has a big effect on the bend. In-process adjustments are essential to ensure right-first-time production at the start of a batch and to prevent scrapped parts.”
He pointed out other features of the LT7 tube laser that promote productivity. One is in-process stud rivet insertion, a possible“ first in the UK.” Another useful feature is the ability to scan the end of a tube and accurately manipulate it to laser cut joints for better weld positioning and penetration, either by robot or by hand. The laser’ s 3D tilt-head sculpts tube ends to sub-millimetre accuracy, not only creating a stronger and more aesthetic join, but also minimising the amount of filler wire used and the need for subsequent fettling.
Examples of Gresham’ s office furniture products.
components. Our latest investments have delivered exactly that,” he continued.
The production team in Bolton was keen that all sheet and tube working machines on the shop floor should be from the same supplier, as modern manufacturing demands a high level of digital integration. It is particularly important that the tube bender can feed back data to the tube laser. BLM was chosen as the supplier due to a successful pre-existing working relationship, which originally dated back to 2001 with the arrival of a hydraulic BLM tubebender( which is still in operation today).
Tube laser cutting and bending
“ Tube processing is a perfect example of how important it is that production machines can exchange data. If a bolt hole is to be cut on the BLM LT7 Lasertube for bending on the E-TURN 52, ArTube 3D CAD / CAM software predicts how much the tube will stretch during the bend and automatically tells the laser cutter to position the hole the relevant distance away from its nominal position. This adjustment is different for the five dozen or so different mild steel and aluminium tube cross sections in stock at the Gresham factory( round, square or open-section) for each wall thickness( which varies from 1.2 to 2.0mm) and for every bend angle,” BLM told ISMR.
If the E-TURN 52’ s axis motor torque sensors and internal laser measurement detect that the metal is stretching more or less than ArTube predicted, causing the hole to be slightly out of position, a correction is sent to the LT7 control to update the program before the next length of tube is cut. Inaccuracy in the bend angle due to springback is similarly measured and compensated, in this case immediately by the E-TURN 52 on the part that is being processed, rather than the next one. VGPNext is the BLM software executing programming of the bending machine and 3D simulation for collision checking.
A camera in the working area of the LS7 allows process monitoring from outside the machine.
David Openshaw added:“ Inter-machine communication avoids problems caused by inconsistency in tube material supplied to us, which can vary in wall thickness by 0.2-0.3mm.
Sheet laser cutting and bending
The BLM LS7 3015 flat-bed laser profiling machine, powered by a 6kW fibre laser and the STR Verde 260-100 press brake, are built to optimise their own performance. Third-party software is in use for these machines: Lantek CAD / CAM nests 2D components into each mild steel sheet to maximise material yield and EsaBend 3D programming and control software oversees press brake operation. It is, however, BLM’ s overarching Prometheus master software that coordinates work orders across all machines supplied by the BLM Group.
“ The fibre laser flat-bed cutting system is engineered for speed with simultaneous axis acceleration of 2g and a high-speed, electrically operated pallet changer that swaps sheets in nine seconds, all designed to maximise production output. The machine incorporates an aluminium gantry on a polymer-concrete base to ensure high rigidity and vibration damping, even during rapid changes of direction of the laser head. The machine is further enhanced by BLM’ s Active Tools, which automatically adapt the laser beam diameter
Square-section mild steel stock being processed on the BLM E-TURN 52 electric tube bender. The E-TURN 52 can produce left- and right-hand bends in the same automatic cycle.
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