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| Figure 1: 19” Rack |
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Figure 2:
19” Cluster
Tool from Mate |
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Figure 3:
19” Cluster
Hole Pattern |
Innovative Solutions for
Sheet Metal Fabricators
by Frank Baeumler
Vice President - Marketing
Mate Precision
Tooling
A common topic of conversation among fabricators is focused on adding more value to their sheet metal components. In addition, fabricators are constantly looking for ways to expand their capabilities and improve their competitiveness. Increasingly, they are turning to their tooling suppliers for help. This quest for improved capabilities is aimed at improving the quality, reliability, and value of their products.
In response, tooling supplies such as Mate
Precision Tooling, combine their fabrication expertise, with
advanced tool design techniques, and an understanding of
the machine to develop innovative custom tooling solutions.
As an OEM supplier to Finn-Power, Mate has a unique comprehension
of the intricate relationship between the machine, the tooling
and the work piece.
Recent examples of these innovative custom
tooling solutions include: a cluster tool designed for the
electronic enclosures industry, an assembly that eliminates
the need for welded fabrications and an application which
simplifies the bending of complex forms.
19" Racking Cluster
The first application is simple, yet effective.
The 19" Racking System is common standard within the electronic enclosures industry. One of the elements of this type of product is a series of mounting holes that are precisely positioned in accordance with international standards DIN41494 and IEC297. See
Figure 1. The 19" Racking Cluster tool from Mate is a solid cluster punch which includes three punch points on 0.625" (15.87mm) centers. See
Figure 2. The machine is then programmed to move the sheet in 1.750" (44.45mm) increments to create the correct hole pattern. The two outer holes are 0.375" (9.50mm) square, while the middle hole is the same size but includes a small protrusion to indicate the center of the pitch. See
Figure 3. Alternate hole shapes and sizes may be specified for non-standard applications. The specially shaped central hole makes it easier for the end user to install components into the completed racks.
This application reduces the punching time
by two-thirds, improves reliability and adds value to the
finished products.
Fabricated Joints Without Welding
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Figure 4:
Ultraform® 1-1/4”
Mate SnapLock™ Assembly |
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Figure 5:
Pre-Painted Components Assembled with Mate SnapLock™ |
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Figure 6:
Sectional view of Mate SnapLock™ |
The second
application eliminates the need for welded joints. Mate SnapLock
is an ingenious method for creating fabricated joints in
sheet metal without welding. See Figure 4.
The assembly allows
users to join materials, even if they are of dissimilar type
and/or thickness, thus eliminating expensive secondary operations
such as spot welding, riveting or fastening with threaded
hardware. This application can also be used with pre-painted
material that cannot be subsequently welded. See Figure
5. With SnapLock, users can create fabricated assemblies efficiently,
effectively and with CNC precision.
How does it work? The
Mate SnapLock tool is a Lance and Form assembly which provides
a self-locking spring-loaded tab that snaps securely into
a pre-punched hole. The small button in the top of the form
is semi-sheared to provide a positive mechanical lock, when
engaged with a hole in the receiving tab. See Figure 6.
Complex
Bending Made Easy
The third application simplifies the bending
of complex forms. Mate EasyBendT is a tool used to create
bend lines suitable for subsequent hand bending operations.
EasyBend is ideal for intricate fabricated assemblies where
conventional press brake forming techniques are inconvenient.
EasyBend is quick, easy and convenient.
Mate EasyBend features
an upper tool with a linear V-line stencil engraved onto
the face of the tool. The lower tool is a blank die. As the
upper tool penetrates the sheet metal a crisp bend line is
created. This makes the sheet metal suitable for subsequent
bending by hand. See Figure 7. The continuous nature of the
design allows the length of the snap-line to a maximum suggested
length of 12 inches (300mm). The angle of the stencil point
is related to the angle of the desired form, which must be
specified when ordered. The actual depth of penetration is
dependent on the ductility and thickness of the work piece.
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Figure 7:
Mate EasyBend™
Forming Sequence |
The maximum suggested material thickness is
0.078" (2.00mm)
for mild steel and aluminum and 0.059" (1.50mm) for stainless
steel. Thicker materials require more force to bend.
By
allowing the component to be bent by hand, complex formed
sections can be created without the need to design and
manufacture custom-made press brake tooling. By combining
EasyBend with SnapLock, it is possible that components can
be shipped in the flat or partially formed state, and then
assembled on-site. This reduces the shipping volume and improves
value to the customer.
Innovative Tooling Solutions
All three of these innovative custom tooling
solutions are designed to help the fabricator to improve
quality, maximize efficiency and add value to sheet metal
components.
For more information,
please contact:
Mate Precision Tooling
1295 Lund Boulevard
Anoka, MN 55303
Phone: 800-328-4492
Phone: 763-421-0230
Fax: 800-541-0285
Fax: 763-421-0285
www.matept.com
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710
Remington Road 
Volume
14 Issue 1 -
July 2004