Rolling
Tool Forming/Etching Technologies
with a Finn-Power Turret Punch
Press
 by
Andrew McCarlie
Applications Engineer
In
many metal fabricating operations, the traditional machine
of choice to produce a large emboss has been the stamping
press due to the size of the die required and the tonnage
needed. Often, this emboss or form is a secondary operation
on a part that may already be punched. The cost of the
die work, the time taken to produce it, and stamping operations
can often translate into additional production costs and
a large minimum product quantity required to recoup tooling
costs.
An
innovative alternative to stamping – depending
on the type and size of form – is the use of an
offset roller ball or wheel technology tool in the Auto-Index
station of a digitally (servo) controlled, adjustable
ram hydraulic or servo-electric turret press. Since a
Finn-Power turret punch press can have up to 10 or 15
(Shear Brilliance/Laser Brilliance) Auto-Index stations,
multiple wheels can be used in one tool setup.
Material
from 26 gauge to 14 gauge CRS (0.078”/2 mm)
can be processed using the offset roller ball/wheel
tool. The tool can produce an embossed form (up or
down) of any size on a sheet. Typical wheel/roller
tool speeds can be up to 1000 ipm or higher depending
upon material type, thickness, and depth of emboss.
The maximum depth of the offset depends on the tool
design. For 0.060 CRS, it is approximately 0.144”/3.7
mm including the material thickness.
Finn-Power
NC Express software. |
The Finn-Power
NC Express software is used to seamlessly program
this type of tool in an easy to use graphical environment.
The offset shape or rib can be programmed using teach cycle
software so that any parts that have the same offset feature
can be auto-tooled rather than having to repeat the programming.
NC Express also enables the programmer to specify the electronically controlled
tool height (S value) by die clearance for each material thickness.
The rolling speed of the tool can be set permanently for the specific material
type and thickness using the die clearance as well. This makes
the programming of parts using this tool very quick and user friendly.
Large rolled stiffening
ribs replace secondary cross braking operations. |
Another
forming operation that adds extra value to a part when
fabricated as part of the punching cycle in the turret punch
press is the stiffening rib. These are normally produced
on a punched part as a secondary operation in a press brake.
This additional handling and braking operation can add significant
cost to a part, particularly if it is very large and heavy,
requiring more than one person in the press brake operation.
The turret punch press using the roller ball/wheel ribbing
tool can produce radial as well as stiffening ribs in up to
12 gauge (0.105”/2.7
mm) CRS. The maximum height in 0.060” (1.5 mm) material
is up to 0.144”/3.7
mm depending on the tool design.
Another use
for a roller/wheel tool is to again combine what is very
often a secondary operation of press braking offset flanges
or joggle bends on punched parts. Once again, this can often
be a time consuming secondary operation that requires
the setup of a second machine, the creation of
work in progress (WIP), as well as extra handling
and storage with its associated costs.
Another useful
tool, which does not require the use of an Auto-Index station
but works in a similar fashion to the roller ball/wheel tools,
is the diamond point etching tool. Again, what is a secondary
operation of custom part marking for logos, features, or numbering
can be done in the same work center as the punching,
forming, shearing, or laser cutting. This tool can create
any number or intricate shapes in any size on your part.
The diamond point tool is spring loaded and comes with
two diamond point tip sizes for fine or coarse line etching.
For
more information on these forming tool technologies, contact
sales@finnpower.com.
|
710
Remington Road 
Volume
13 Issue 2 -
December 2003