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Long-Term Commitments Pay
Dividends for
Midwest Job Shop
Kenneth Kuzelka, chief executive
officer of KSO Metalfab, Inc., and his mother Dora, the
company's president. |
From
the first day KSO Metalfab, Inc., opened its doors in 1973,
the company made a commitment to utilize the latest technology
in order to provide its customers with the highest quality
products at competitive costs. For three decades, which
included moving locations and progressing through several
generations of machines, the management of KSO has kept its
pledge to its customers. As a result, the company has been
rewarded with steady growth. Today, this family-operated
contract manufacturer has 45 employees and occupies a 40,000-square-foot
facility in Streamwood , IL . KSO provides comprehensive
services, turnkey project management, and full engineering
support. The company serves OEMs in such industries as
computer, fast food, automotive, transportation, telecommunications,
medical, coin operation, gaming, and electronic equipment.
KSO has sought the same type of commitment from its fabrication
equipment suppliers. One such relationship was created in
1986 with Finn-Power International, Inc., Schaumburg , IL
. "We purchased our first Finn-Power hydraulic turret punch
press shortly after it was introduced to the North American
market," explains Kenneth Kuzelka, KSO's chief executive
officer. "It was the first of eight Finn-Power machines that
we've purchased."
"Through the
years, Finn-Power has been an industry leader in introducing
new technology. We purchase
Finn-Power machines because
they provide manufacturing solutions to our production
needs."
True to their word, KSO management kept their
eyes open for advancing technology and frequently "traded
up" for newer
and more advanced Finn-Power machines. "Through the years,
Finn-Power has been an industry leader in introducing new
technology," says Kuzelka. "We purchase Finn-Power machines
because they provide manufacturing solutions to our production
needs."
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The Finn-Power Laser Punch provides punching, forming, tapping, and laser cutting in a single unit for the most varied sheet metal working operations.
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The eight Finn-Power machines have included six hydraulic
turret punch presses, a press brake, and in 2000, the Laser
Punch FMC. Today, the TP 2525 turret punch press, the hydraulic
press brake, and the Laser Punch are in operation at KSO. "We
were getting more customer requests for more complex parts
and heavier gauge materials," says Kuzelka. In order to satisfy
its need for increased punching and laser cutting, KSO purchased
the Finn-Power Laser Punch in 2000.
The Finn-Power laser/punch combination represents a proven
technology and intelligent integration of punching, forming,
tapping, and laser cutting in a single unit for the most
varied sheet metal working operations. Optimum use of the
Finn-Power Laser Punch means a fabricator can use the turret
punch press where it is easier or faster and the laser where
it is most effective. The Laser Punch allows the user to
look at the parts, the materials, the time, and the overall
cost of the parts to determine the optimum process for every
production.
Other benefits of the Laser Punch include:
Reduction of piece part costs - faster
punching time, reduction in direct labor assigned to
set up and punching, reduction of number of manual operations Utilize full sheets while eliminating
the need to shear to size blanks being processed Increased machine utilization - if
a loading system is purchased with the Laser Punch, unmanned
operation can be achieved from load, punch, upform, laser
cut, and sorting of parts in one machine
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High-pressure cutting
with a TRIAGON 2500 watt CO2 laser with 375 psi (25
Bar) assist gas pressure maximum. Higher pressures
allow for cutting materials such as stainless steel
and aluminum with optimum speed and edge quality.
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The Laser Punch consists of a F-6 hydraulic turret punch
press with a laser that has a 60" (1500 mm) "Y" axis and
a 100" (2500 mm) "X" axis and a 2.5kW laser. "The Finn-Power
allows us to automatically load and unload material. We can
now process full-sized sheets and no longer need to shear
the material into blanks. We have dramatically cut costs
on material handling, shearing, and such secondary operations
as deburring," explains Kuzelka.
The Laser Punch features include:
High-pressure cutting with a TRIAGON 2500 watt CO2 laser
with 375 psi (25 Bar) assist gas pressure maximum. Higher
pressures allow for cutting materials such as stainless
steel and aluminum with optimum speed and edge quality. The oil-free design of the pumps and turbines eliminates
expensive and time-consuming repairs. Excellent energy consumption is realized by the laser
in comparison with other HF-excited lasers. The savings
cost can be up to 40%. The capacity of the laser is
8 mm (.314") cold rolled
steel, 6 mm (.234") aluminum, and 8 mm (.314") of stainless
steel. The focal length lens can be
changed in seconds using a cartridge technique. No tools
are required. The cartridges are available in 5" (standard), 3.75" and 7.5". Integration of the laser and the punch is accomplished
with the part piece flowing from the turret punch press
to the laser without the release of the clamps. The flow
of material is from the load side to the unload side, eliminating
the time-consuming method of loading and unloading from
the same side.
 In addition, the O-frame of the turret punch press is separate
from the laser, assuring that no vibration will be transferred
to the laser. Up to 10 auto-index, forming, and Multi-Tool® holders
may be installed in a Finn-Power turret. KSO has three Multi-Tool® holders:
two 8- and a 24-station that help cut tool-changing time
between set-ups.
Finn-Power's approach to auto-index is completely different
than that of any other builder. The system precisely rotates
the punch and die in their tool holders using a single A.C.
servo-motor system. The system does not need to match different
servo-motors as in other machines. Rotation in .001 degree
programmable increments gives the machine the ability to
rotate infinitely beyond 360 degrees.thus allowing the system
to automatically select the shortest path to rotate to a
programmed angle input into the NC programs with simplicity,
speed and reliability. KSO has seven auto-index stations.
The auto-index system is built rigidly into the upper and
lower frame of the press and engages the auto-index tool
holders for tool rotation. This system allows you to add
or change the index stations or Multi-Tool® stations
at anytime. In addition, the Finn-Power turret can run any
new wheel technology and marking tools available from Mate
Precision Tooling or Wilson Tool International. There are
no additional options (i.e. holders or software) required
to run these technologies.
Other features of the F Series turret punch press include:
Programmable Clamp settings (PCS) is a Finn-Power patented
feature that controls the central locking system of the
sheet clamp system. PCS provides automatic positioning
of the work clamp according to the NC program. By setting
PCS at the beginning of an NC program, the CNC control
positions the clamps, automatically keeping them from traversing
to an unwanted position. A third sheet clamp together with PCS enables a clamp
to be moved during the program. This feature eliminates
dead zones and allows 100% of the material to be utilized. Brush tables are standard on all Finn-Power turret punch
presses and provide for better material support during
punching, noise reduction and reduces surface scratches.
"The
Finn-Power Laser Punch has opened new markets to
KSO. We also do a great deal of prototype work. The
personal commitment that I have received from Finn-Power
over the years keeps me from even looking at competitors'
products."
Another unique feature is Finn-Power's
upforming system which allows full tonnage throughout
the punch stroke in an upward movement in the turret
which provides maximum flexibility in achieving various
forming options. Unlike conventional forming operations
in other machines, the Finn-Power upforming solution
provides the capability of the die to never rest higher
than the table level when the sheet is being moved,
thus eliminating machine downtime due to sheet crashing.
The even positioning of the die also
provides greater limits in forming height (up to .63" or
16 mm in total height) and prevents free sheet movement
and scratches on the lower sheet surface (this is of
particular importance with coated materials or materials
where cosmetics is critical).
"The Finn-Power Laser Punch has opened
new markets to KSO," says Kuzelka. "We also do a great
deal of prototype work. The personal commitment that
I have received from Finn-Power over the years keeps
me from even looking at competitors' products." |
KSO provides turnkey
operations for its customers. The company serves
OEMs in such industries as computer, fast food,
automotive, transportation, telecommunications,
medical, coin operation, gaming, and electronic
equipment. |
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710
Remington Road 
Volume
13 Issue 2 -
December 2003