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Articles tagged with "single"
Results: 85
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Cutting through the obstacles: The challenges of sawing structural tube, pipe, and solidsOf all the materials that can be cut on industrial band saw machines, structural steels—such as pipe and tubing, plate, angle and channel iron, and I beams—are all among the most common and challenging.
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Band saw cutting of tube and pipe: Tips for blade selection and machine settingsProduction quantities of cut tube and pipe can be produced economically with a band saw. However, the choice of which blade to use is very important in maintaining a low cost per cut.
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Take the old with the new - Selecting saw blades with new technologies in mindNew methods for cutting tube and pipe have been introduced to welding shops in the last few years—methods designed not only to cut metal, but also to cut costs.
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Not your father's abrasive jet: Technological advances, attention to common woes give fabricators options for precision cuttingThe advances made in abrasive jet cutting in recent years have negated much of the downside formerly associated with the technology.
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Exploring complementary cutting methods: Comparing capabilities of laser, plasma, EDM to waterjet technologyThe various cutting methods available to fabrication shops today can be both a little daunting and very beneficial. Choice is good--learn how to make the most of the diversity all your choices offer to you.
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Selecting a table for abrasive jet machining |
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Fabricating technology advancements drive new plate finishing trendsThe same industry forces of nature—globalization, economic conditions, quality demands, and safety and environmental regulations—that are pressuring metal fabricators to do more, better, and faster with less are blowing no less forcefully on finishing fabricators.
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Blast Cleaning Equipment: What you need to know before buyingIf you are a fabricator of metal parts that need to be primed or painted, then you more than likely will have to prepare the part surface before finishing to produce the desired end result.
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Choosing the right coated abrasive for plate finishing applications: A look at grain propertiesMost plate fabricating companies need to select a coated abrasive to finish their parts. This selection process can be intimidating, as well as confusing, because so many types of coated abrasives are available.
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Folding technology makes sweeping changes: New developments in 200-year-old technologySchwenkbiegemachinen, or swing bending machines, have been in use for more than 200 years. European manufacturers began to power them with electrical or hydraulic power after World War II, when an enormous amount of sheet metal was used in the reconstruction of Europe.
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Successful tube hydroforming: Watching parameters, accurately simulating the process yield good resultsA typical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy).
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Hydroforming of tubes, extrusions, and sheetRecent advances at the University of Stuttgart and acfross the industry have opened doors for hydroforming all kinds of materials and shapes.
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Effective simulation of hydroforming: Current capabilities and requirements for the futureSimulation is used in the hydroforming process to replace the experimental investigation and tests required in a real tryout process.
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Dealing with internal pressure in free hydraulic bulging: Predicting results with FEAFor hydraulic tube bulging, direct pressure control is the most commonly used process. Pressure control allows engineers to determine the correct capacity hydraulic system and, more importantly, prevent tube rupture. However, inflow control, or control of the volume of fluid inside the tube, theoretically could be another viable hydroforming process. Finite element analysis has shown that inflow control could allow engineers to more accurately predict deformation behavior and therefore enhance the hydroforming process.
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What's that material?: Using XRF technology to identify alloysMany alloys—stainless steels, HASTELLOY®, INCONEL®, INCOLOY®, MONEL®, duplex and superduplex alloys—are similar in appearance and easily mixed up after mill test reports (MTRs) and heat stamps are removed in material processing. These mix-ups can have serious consequences to the end user, including product rework, factory downtime, or premature product failure. A single mistake may cost hundreds of thousands of dollars in materials and labor to correct. In addition, any loss of consumer confidence resulting from shipping incorrect material carries incalculable costs.
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Phases, structures, and the influences of temperatureWhen you heat or cool a piece of metal to a specific temperature, that metal goes through what's called a phase change, in which its crystal structure changes. Sometimes the change is obvious. For example, when a piece of metal melts, it goes through a phase change when the crystal structure breaks down and the metal goes from solid to liquid. When it solidifies it's also a phase change, as the structure re-forms from liquid to solid.
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Combating plate corrosion: Improving corrosion resistance through welding, fabrication methods |
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Ensuring a plant's electrical system safety: One company's experience with infrared thermographyThis article takes a look at using infrared thermography in the plant setting to detect potential fire hazards. It discusses who can provide the service, what sorts of problems it can detect, and generally explains how the problems discovered when using this technology should be handled. It also uses an actual inspection as a basis for the discussion.
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Working safety with metalworking fluids: How to protect workers from their harmful effectsThis article examines the hazards associated with metalworking fluids. Health effects, including skin and respiratory disorders and cancer, are addressed. A look at engineering and administrative controls that can be implemented to ensure the safe use of metalworking fluids is included.
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Your best safety resource: The FMA/CNA Safety CommitteeDo you know the Fabricators & Manufacturers Association, International™ (FMA)/CNA Safety Committee? If not, you should. They're an excellent resource for guidance on workplace safety issues. And they're the force behind the safety focus on thefabricator.com.
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Six dangerous misconceptions about crane safety: Knowing the facts could save your lifeKnowing how cranes should be used, and how they should not be used, is critical to crane safety. Overload, side pull, limit switches, secondary braking devices, using the reverse direction for speed control, and daily inspections are surrounded by myth and mystery in the workplace.
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Protecting yourself from gases and fumes: 10 tips for healthier lungsWelding gases, fumes, and smoke can cause both short-term and long-term health hazards for welders. Presented here are 10 ways to help ensure welders are kept safe.
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Having a safe office party |
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Mac's Muse: One potato, two potatoes, three potatoes ... gone! As U.S. steel industry gets its lunch eaten, many parties can share blameA lot of parties can share the blame for what's happened to the North American steel industry, and its going to take effort from them all to pull the industry out of its quagmire. Can it be done? Time will tell.
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Steel industry anything but status quo: Next generation of distributors set to lead wave of changeAs the market demands change, the steel distribution industry will take up the gauntlet and change with the times. Contrary to some speculation, the steel manufacturing industry is neither going away nor reluctant to embrace the innovations necessary to survive.
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Common barricades on the road to leanThe number of opportunities to steer your company wrong during a move toward lean manufacturing are myriad. Knowing a few of the common ones may help you achieve your goals without a lot of headaches.
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Tips on Lean Manufacturing: How to purge weight from your manufacturing operationAll manufacturing operations need to reinvent themselves to compete in today's marketplace. What can you do to change? Try going lean.
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Changing the way they do business: Bridge, structural fabricators have to think about process choicesDealing with work loads, delivery schedules, and many other responsibilities doesn't leave managers with much time to consider factors that justify equipment improvements.
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Overcoming organizational paralysisParalysis – what a horrible thought. What if you found yourself in a situation in which you had partial or complete loss of motion and sensation in your body?
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Tuning a piano—making the most of your best resources |
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Getting it Straight: Understanding coil straightening in stamping operationsBefore coiled material can pass through a die to produce an acceptable part, it must be straightened. Coil straightening is accomplished by bending a strip of material around sets of rollers that alternately stretch and compress the upper and lower surfaces so that the material's yield point is exceeded.
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Examining press feeding options: Considerations that determine a feed's effectivenessPress- and servo-driven roll feeds and gripper feeds are almost as common to the stamping industry as sheet metal and dies. Knowing how to use them effectively may not be so common.
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Metal stamping and electromagnetic forming: New process improves material formability, reduces wrinklingThis article describes the development of electromagnetic forming (EMF) and how EMF works.
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Hydraulic workholding from scratch: How to select and set up componentsHydraulic clamps are used in place of manual or toggle clamps to hold the workpiece or tool in place during stamping. This article examines the four steps that comprise the selection and installation of a hydraulic workholding system: cylinder selection, cylinder force and stroke, power source selection, and system connection.
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Experimenting with flexible blank holder force control: Prototype shows promise for difficult-to-form materialsThe quality of deep drawn sheet metal products is determined largely by the rate at which a sheet is drawn into a die. Varying blank holder force (BHF) as a function of time or the press stroke is of great importance.
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Robotic press tending: vailable equipment and its effects on press productivityRobots offer an alternative to automatic transfer presses in applications in which parts must be reoriented (tilted, rotated, or flipped) as they are moved between operations. When selecting a robot for press tending, three of the many features to be considered are size, flexibility, and mountion options.
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Auto industry demands shape the future of stampingAs the stamping industry heads into a new century, it continues to be driven primarily by the automotive industry.
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Standardizing finger tooling: Modular systems provide alternative to dedicated transfer toolingModular, adjustable, articulated finger tooling for transfer presses may provide the flexibility you need to increase productivity and efficiency in your stamping operation.
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Appliance industry takes a shine to powder blank technologyAmong European, Pacific Rim, and U.S. appliance makers and other manufacturers with large-scale, appliance-grade finishing requirements, the use of powder blank line coating systems has grown steadily during the past 10 years.
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Stamping 101: Chicago-area training facility offers a hands-on educationTo promote real-world stamping training, the Tooling & Manufacturing Association (TMA) wanted to create a resource whereby stampers could receive a consistent, recognized, hands-on education on the industry's most current equipment.
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High-tech presses: Servo technology meets mechanical presses |
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Filling in the blanks: What to look for in an in-house blank shearing line |
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Key design principles for successful deep drawingSuccessful deep drawing depends on many factors. Ignoring even one of them during die design and build can prove disastrous.
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Controlling flow and obtaining stretch in deep draw operationsAddressing the difficulties in obtaining a wrinkle-free stamped part requires a good understanding of metal flow and how it is affected by draw beads
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Part nesting and die design tips for reducing and utilizing scrap in stamping operationsYou might be able to gain a competitive edge by learning how to reduce the amount of engineered scrap, or that material that was inteded to be scrap rather than scrap created because of defective piece parts.
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Incorporating available technology into die design: Tools of the trade are evolvingDesigning progressive dies has increasingly become a high-tech process. The more able an operation is to use computer technology, the more able it is to use the latest advances in the field in its own designs.
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Protecting dies against press system faultsThe need for die protection has existed ever since the first die was produced. The most elementary form of protection has always been an alert, dependable operator. However, an operator cannot always react to a problem before it damages a die.
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Improving blank edge conditionsA blank, stamped in the first station of a progressive stamping operation, usually is subject to subsequent forming processes to form a designated part. If the blank is subject to straining, deformation, bending, stretching, or lateral expansion in later stations, its edge condition should be carefully examined.
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Selecting a stamping die pressure system, Part II |
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Venturing Into the World of 3-D Die Design: 10 questions to ask to make an informed decision2-D, or not 2-D; that is the question. Whether 'tis nobler to venture out into a brisk, bold, new world of 3-D or to stick with old, reliable methods in 2-D.
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Orbital welding for space program applications: Producing welds that withstand the rigors of deep spaceWelding applications in the aerospace industries demand high precision, a quality that can be entirely as low as possible. Automatic orbital welding is being used to help meet these requirements.
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Automating your end forming operation: How to maximize efficiency in the shopEfficiency, productivity, and quality are focal points for end forming operations, and many manufacturers are looking to automation to improve those dimensions of their businesses.
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Producing holes in tubing: Comparing the piercing and punching methodsNeed to put a hole in a tube? This article provides an overview of tube punching and tube piercing, exploring the different variations of each method and comparing the two methods on cost, safety, and flexibility.
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Automotive motives - Tips for cutting per-piece prices for automotive customersToday's automotive industry is more competitive than ever. To compete with the European, Mexican, and Asian markets, the U.S. market must become more aggressive in finding ways to cut costs.
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The Bold in Arches: Pipe fabricator uses induction bending to create roof truss assembliesThe phraseobstructed viewis probably most connected with older sports stadiums. For example, at Wrigley Field in Chicago, depending on where your seat is, watching Sammy Sosa in action in right field might be replaced by a view of a rusting steel girder.
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Using finite element analysis to roll-form tubesRoll forming is a common method for producing steel tubes. It is a continuous process in which a strip is guided through several sets of rolls that form the strip into the desired shape. After the final shape is achieved, tube edges are welded together to form a closed section. After the welding operation, the tube is sized through another set of rolls to obtain the required diameter.
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Taking tubular aluminum scaffolding to new heights: Taper, aesthetics, elevated design for monumental structureFor the company that broke the world record for building the tallest freestanding structure with a 320-foot scaffolding (the Statue of Liberty restoration project in 1984, see Sidebarat bottom of page)designing and constructing the scaffolding for the Washington Monument restoration project was just a natural next step.
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Structural tube on campus: Aluminum bridge spans science departmentsCentral Washington University in Ellensburg, Wash., is known for its strong science programs. "Flying Bridge," a structure designed by artist and sculptor Ed Carpenter, physically and metaphorically spans the biology and chemistry departments in the university's new Dean Science Building. Carpenter, who designed the bridge with engineering consultation from Peterson Structural Engineers Inc., teamed up with Albina Pipe Bending Co. Inc. to tackle the project's material bending and fabrication requirements.
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Flying high with orbital welding: Equipment, applications, and joint designs for aerospace componentsOrbital welding first was developed in the late 1960s by a group of engineers from McDonnell Douglas to join aerospace tubes. These engineers were aware of the problems associated with producing repeatable welds for their critical applications.
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Making seamless tubing with a floating mandrel mill |
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Solving Problems on the Tube MillTube mill operators face a variety of challenges everyday in their efforts to produce high-quality tubing in a cost effective and productive way.
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Comparing single-cut and dimple-free tube mill cutoffs: When to employ each systemThis article covers the application of single-cut and dimple-free cutoff shear technologies as they are applied to contemporary high-speed tube mills.
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Examining tube mill roll tooling, setup, and maintenanceIn today's competitive market, two of the most important considerations for high-quality production are proper roll tooling setup and mill alignment.
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Plotting for success: Using edge thickness measurements to aid troubleshootingThe butler slipped through the pantry area with the warm milk and, after adding some arsenic, served the beverage to his master. The butler had been gradually increasing the amount of arsenic over many months, so the change in the milk's taste wasn't noticeable. Soon the mistress and her nefarious servant would be rid of the one thing stopping their affair.
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Al GMAW: CC or CV?For about 40 years, a great debate in welding is whether to use constant-current or constant-voltage power supplies when using gas metal arc welding on aluminum. Constant-current power supplies made sense 30 years ago and are still used in some applications today, but for most applications, constant-voltage power supplies are suitable for gas metal arc welding aluminum.
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Welding aluminum with inverter-based power suppliesIt's easy to look at such a long-established technology as welding and believe that little or no technology development is taking place. In truth, however, the capabilities of welding power supplies are changing constantly and rapidly, especially in the area of inverter technology. These power supplies are suitable for welding aluminum alloys, including thin aluminum alloys.
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Choosing a GMAW machine for occasional aluminum welding |
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GMAW vs. FCAW for beginners: Choose the best process for your small operationThere are several pros and cons to using the gas metal arc welding process versus the flux cored arc welding process in compact applications.
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Advantages of plasma welding: Often-overlooked PAW offers speed and affordabilityPlasma arc welding sometimes offers greater welding speed than gas tungsten arc welding at lower cost than laser beam welding.
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Using inverter technology: FAQs about inverter-based plasma cuttersBusinesses feel a constant pressure to gain an advantage and control their processes better. However, the decision to embrace new technology often leaves them feeling vulnerable. In the realm of hand-held metal cutting operations, one such decision is choosing between traditional technology and an inverter-based plasma cutting system.
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Choosing the right oxyfuel gas and supply systemMixing oxygen with fuel gases for brazing, cutting, heating, and welding metal has been around since the early 1900s. Oxyfuel processes have remained in use over the years despite the introduction of other metal fabrication processes, such as arc welding, plasma cutting, and laser materials processing. Finding the most economical method for supplying oxyfuel gases requires a basic understanding of the process.
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Reviving the past: Welding students restore ironwork to Victorian-era YMCA building |
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Designing for successful robotic arc welding automationFor a fabricator to enjoy the benefits afforded by a robotic welding system, the parts to be welded and the system itself must be designed properly.
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Automated welding for job shopsA robotic weldingsystem represents a significant capital investment for a job shop.
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How to Kill a Robotic Project in Five Easy StepsHow would you like to fail utterly in your quest to modernize your shop with robotic weldingequipment? Look no further—we've got all the bad advice you need right here.
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Laser-integrated robotics for assembly: How one job shop met an aluminum welding challengeIn recent years laser welding has advanced into many different industries, from automotive to electronics. With lasers, it is possible to weld at high speeds with great efficiency. Once unthinkable applications and processes are now being developed into working systems.
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Programming multiple robots: Operating two or more robots from a single point of controlIn many applicatios -- such as large-component welding, press-tending lines, and multiprocess cells -- running multiple robots from a single point of control assists in preventing collisions, simplifying the programming structure, and reducing integration cost. This approach also meets the American National Standards Institute/Robotic Institute of America (ANSI/RIA) R15.06-1999 safety standard.
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Shielding gas consumption efficiency-- Part I: Spend a penny, save a dollarInstalling a bulk delivery system in your welding shop is perhaps the best way to save money
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Identifying the right cutting and welding tips: Understanding torch tip design and function |
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Supporting the defense: Manufacturer uses direct diode laser to weld missile canisters |
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Revving up weld quality: Ford Development Center uses RW system to reduce costs, improve quality |
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Brake Line: Press Brakes and More: Planning to cut corners on safety?Press brake safety is a common sense issue.
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In search of the perfect bend: Advancements in press brake angle measurement and bend springback systemsPress brake manufacturers have made tremendous advances in the art of machine design and manufacturing.
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Adaptive bending: Achieving accurate first-piece bending resultsAdaptive bending allows press brake operators to measure a bend angle during the forming process and feed the information to the numerical control. The article discusses springback and how to determine it and the fact that when air bending, 90 percent of problems result during initial setup, and only 10 percent result from springback. It also discusses using an angle control system, methods of measuring angles, and requirements for angle measurement systems.
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Turning up the power: Using lasers to cut thick plateThe most common power levels ranged between 1,500 and 2,000 watts. However, a statistical survey conducted by the AMT Laser System Product Group indicates a steady increase during the last 12 months of installations for high-power 3,000- to 4,000-watt laser systems and a decline in sales of lasers with power levels less than 2,000 watts.
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