It is all carried out on a Mazak Fabri Gear 220 ll laser
tube cutter, pre-installed with Mazak’s FG-CAD/CAM,
a software powered by RADAN’s laser tube system,
Radtube. This processes the most complex pipe and
box section shapes in a fraction of the time taken by
traditional methods.
“It replaces what we used to do manually, which was
to take an eight-metre length of steel, cut it to the
length we needed for the component on our piece of
apparatus, mitre it and put the holes in.”
Another major advantage is that it enables tabs to be
created in a style that the apparatus can only be put
together one way. “We use different sized tabs and
make them non-symmetrical, so when the welder
comes to fit the pieces together it’s like a jigsaw
puzzle, completely eliminating human error at the
assembly stage,” says Simon Watson.
The software can also readily program a scalloping
out procedure, giving added strength to the joints.
“It does everything we were doing by hand…and a
lot more besides, such as the tabbing. Previously we
had to draw both the tabs and slots. But now I just
click where I want the tab, input the gap around it,
and it automatically inserts the slot immediately.
The software really is phenomenal. It’s definitely
transformed the way we manufacture, by automating
around 80 per cent of the manual work the welders
were doing on cutting and preparation.”
invest in a laser tube cutter. “As well as the actual
cutting being so time consuming, there was a lot
of downtime for changing blades and maintaining
saws. Also, when someone’s cutting lengths of steel
20 times, they’re not going to get all 20 to the exact
same length.
Another part of the process that the Radtube-
“But with the laser tube cutter CNC machine and
powered FG-CAD/CAM speeds up is where Simon
specialist software we noticed massive improvements
Watson is designing box section components which
in time and accuracy right from the start. And it’s so
are identical, except for the addition of holes...mainly easy to use. I felt quite comfortable doing basic tasks
for the frames of their weight machines. “One side
after just one day’s training. Within a couple of weeks
may have numerous holes in it, but none in the other. I was completely comfortable doing anything.”
Instead of having to draw it twice, I draw it once with
the holes, create a mirror image, and put everything
Concluding, Simon Watson says: “The Fabri Gear
into FG-CAD/CAM and simply take out the holes.”
and FG-CAD/CAM makes everything consistent and
uniform, and also means if we need to replace any
The company has used a Mazak mill, flatbed laser
parts on an existing piece of apparatus we know the
and two lathes to cut other components for several
new part will be completely accurate.”
years. But it was seeing how much time the welders
www.radan.com
spent manually cutting and processing the box
sections that prompted him to take the next step and
.
TUBE NEWS September 2019 5