- Home
- MyFab
- Tech Cells
- Assembly
- Automation and Robotics
- Bending
- CAD/CAM Software
- Cutting
- Finishing
- Folding
- Hydroforming
- Machining
- Materials Handling
- Metals/Materials
- Power Tools
- Punching
- Roll Forming
- Safety
- Shop Management
- Stamping
- Testing and Measuring
- Tool and Die
- Tube and Pipe Fabrication
- Tube and Pipe Production
- Welding
- Article Search
- Industry Directory
- Publications
- Advertise
- Media Center
Tags
Articles tagged with "time"
Results: 258
 |
How to avoid the top 10 problems in plasma cutting: Practical tips you can use right nowAttention to detail at the outset can save plasma cutting operators a load of trouble during production.
|
 |
What to know before selecting a manual plasma cutter: Understanding size, power, components, costThe first plasma arc cutting (PAC) systems, developed in the '60s, were 1,000-amp monsters designed to blast through 6-inch stainless steel.
|
 |
Plasma pleases plentyTechnological developments in lasers are positioning them as an attractive alternative to plasma. But fabricators are still sticking with plasma cutting for many applications where speed and cost-effective operation are concerns.
|
 |
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.
|
 |
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.
|
 |
Making hands-free straight, saddle, and miter cutsRovanco Piping Systems Inc. designs and fabricates piping systems for applications such as water (hot and cold), steam, and jet fuel. It sells fabricated pipe—typically with straight or miter end cuts—up to 36 inches in diameter. It provides preinsulated, high-temperature, low-temperature, and containment systems.
|
 |
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.
|
 |
Selecting a table for abrasive jet machining |
 |
Advancements in waterjet technologyWhen Jack Budd, president of Precision Waterjet, Orange, Calif., purchased his first waterjet system seven years ago, he expected most of the company's work to come from the aerospace industry, which was robust at the time. When business from that industry tapered off, he searched for new customers in the architectural, signage, and automotive aftermarket industries.
|
|
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.
|
|
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.
|
 |
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.
|
 |
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).
|
 |
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.
|
 |
Using hydroforming aluminum components versus steel stampings: The contender gains points, but the champion is still in the fightThis article examines two transitions that are occurring in the automotive industry—the change from stamping to hydroforming, and the substitution of aluminum where steel was used previously.
|
|
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.
|
|
Pressure-sequence and high-pressure hydroforming: Knowing the processes can mean boosting profitsPressure-sequence hydroforming can form complex parts as well as forming most ductile metals, including high-strength, low-alloy, and stainless steels with sharper corners, thick-walled tube, and other difficult features.
|
|
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.
|
 |
Tier 1 supplier builds four-stage competitive strategyF & P Manufacturing Inc., a tier-one automotive components supplier, focused on four areas when it developed a hydroforming line for manufacturing Honda Accord engine cradles. These areas were eliminating end scrap, decoupling the bending machines from the manufacturing line, reducing cycle time, and palletizing parts.
|
 |
Making the most of hydroforming: Pursuing product potential and possibilitiesHydroforming has become a competitive metal forming method and has succeeded in many applications because of its weight- and cost-saving attributes, elimination of joining operations, and ability to offer part design for confined spaces.
|
 |
Eliminating final trim shearing of hydroformed tubeThe most common way to establish tube length after hydroforming is by cutting or shearing the tube to a specified dimension; however, cutting out this step can reduce scrap. A new method designed to eliminate this step combines forming the end of a tube to resemble its final form with using a hydroform die to correct end position variations off the bender. While this approach eliminates the final shear trim operation, it also presents new challenges.
|
|
Tube Hydroforming Design Flexibility—Part IV |
 |
Hydroforming heats up: New techniques and equipment push industry forwardHydroforming was one of the fastest-growing metal forming technologies during the 1990s. Most of U.S. industry cooled down during and after the recession of 2001, but things have been heating up lately, and the world of hydroforming is no exception. The North American Hydroforming Conference and Exhibition (Sept. 29 – Oct. 1 in Dayton, Ohio), which was sponsored by the Tube & Pipe Association, International® (TPA), and the Society of Manufacturing Engineers (SME), showcased new techniques, equipment, and applications that are moving the industry forward.
|
 |
Handling metal stamping wastes: Protecting the environment - - and your businessMetal stamping companies are required to comply with a number of regulations relating to the collection, transport, treatment, and disposal of the wastes they generate. As a result, each company must learn which materials are classfied as hazardous and how to comply with detailed regulations.
|
 |
Roll out the shelvingJust as office managers look for the most efficient way to store files, shop managers must look for efficient ways to store heavy, expensive dies. Many offices have file cabinets with an index system for locating files quickly. The shop equivalent for storing and retrieving dies may be air-powered rollout shelf units.
|
 |
The importance of storage planningMaterial and equipment storage can be a major concern for fabricators. Therefore, it is important to establish the purpose of a storage system and understand clearly what it needs to accomplish.
|
|
Interaction of chemicals used in forming and fabricatingKnowing how chemicals tend to react with one another and how each type of lubricant and coolant commonly used during steel processing tends to behave is a boon when you're trying to fabricate products properly.
|
 |
Mixed Metals Reactions: Danger in the ductworkUnder controlled conditions, aluminum and steel powders can be mixed to create a chemical reaction to produce heat for welding. If you mix these materials under uncontrolled conditions, you will want to call the fire department.
|
 |
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.
|
 |
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.
|
|
Combating plate corrosion: Improving corrosion resistance through welding, fabrication methods |
 |
Making steels strongerWhen it comes to modifying a steel's strength and hardness, it's important to not confuse hardness with hardenability and remember that hardenability characteristics are important because they help identify how much a specific steel will harden during welding.
|
|
Keeping pace with today's punching requirements: Advancements in tool design, metallurgy lead to more accurate holes, improved part qualityThis article provides the basics on how the punch, die, and stripper work; how to perform material thickness calculations on various materials; how different applications affect punching quality; how fully guided tooling counters lateral forces; and how metallurgy, coatings, and maintenance affect tooling.
|
|
Punching tips: The easiest solution to slug management is to keep the tooling in good conditionThe author discusses what not to do to manage slug ejection. He mentions several tooling maintenance errors that he has made over the years, as well as what machine operators can do if they want to experience slug ejection difficulties. He concludes by stating that the easiest solution to slug management is to keep the tooling in good condition and to use the correct die clearance for the material.
|
 |
Roll formers look for a win: Industry players hope to score with customization, better technology |
|
Thermal spray safety and OSHA compliance: Protecting operators from ultraviolet light, fumes, dust, compressed air, gasesOSHA has regulations for both facets of thermal spray environment, and shops should be aware of some practical safety tips for how to comply with those regulations.
|
 |
How to avoid getting burned by hot work: Preventing losses and insuring safetyMaintaining a safe work environment in facilities in which hot work, such as welding, is done can be easier said than done. Measures such as preventive safety, safety zones, and fire watches can keep employees safe and worker's comp time down
|
|
Stamp of Approval: Full-court press safety: How to maintain an effective safety program end to endIf you want a safe press operation, look beyond the machinery. Don't be surprised to find the keys to a good safety program well outside the confines of the pressroom.
|
 |
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.
|
 |
A breath of fresh air: ArrayArray
|
|
Assessing cutting and forming machine tool safetyThe expanded breadth of recent standards typically includes the entire life expectancy of machines, the full scope of possible risks, the frequency and severity of risks, and the possibility of harm.
|
|
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.
|
 |
Common threads in workplace safety: How different committees work to ensure the health and safety of their workersAlthough various safety committees differ somewhat from plan to plan, they all function as a means to promote workplace health and safety. Different components of a safety plan include responsibilities, activities, and the structure of each company's committee.
|
 |
Proper guarding protects workers: Six steps to focusing on your employees' needsWhen people think of machine guarding, usually they think of devices to protect people from the moving parts on machinery.
|
 |
When sparks fly ...This article combines examples of fires caused by inadequate protection from welding with information on heat-resistant textiles and how they can be used to provide that protection.
|
 |
Dressing for success and other welding safety tipsWhether we are attending a social occasion or dressing for the job, we all give some thought about what we are going to wear.
|
|
Defibrillators—Should you have one in your workplace?This article explores the facts about AEDs, the legalities surrounding their use by laypersons, and guidelines for implementing an AED program in the workplace.
|
|
Making the workplace safe for Spanish-speaking employeesModifying your safety program to address the needs of your Spanish-speaking employees can create a much safer work environment. Here's how one company achieved that goal.
|
|
Workplace stress—Part 1Stress is a fact of life. It's here to stay, and even if we could abolish it, we wouldn't want to. At its best, stress can be the catalyst that moves us to make changes and achieve great things in life. At its worst, it can create all kinds of emotional and physical problems. What determines whether stress is a friend or foe? Whether it precipitates changes that improve our lives or whether it greatly diminishes the quality of our lives? One determining factor is how we handle or manage stress. We can be our own best friend or our own worst enemy.
|
|
Workplace stress—Part 2If you've visited a doctor recently and were told that stress is the cause of or a contributing factor to what ails you, you're not alone. Although you can't expect to eliminate all of the stress in your life, you can learn to manage it and reduce its negative effects.
|
|
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.
|
|
Selecting the best lens for welders' eye protectionIn the industrial environment, safety glasses are a necessity for jobs that put employees' eyes at risk of exposure to heat, impact, chemicals, or dust. But workers also need protection from nonimpact dangers, such as radiant energy, eye strain, and fatigue. So choosing the appropriate lens or filter plate for your workers' eye protection is just as important in preventing eye injury as is selecting the appropriate style of safety eyewear.
|
|
Promoting back safety—one company's approach |
|
Having a safe office party |
 |
One system does not fit all: Ventilation equipment becomes more specific to improve the welding environmentVentilation systems come in a variety of types for different types of welding processes and varying fabrication facility setups. The emphasis on proper application of these systems and best use of the components used in them comes from an increased interest in cleaner air for the welder.
|
|
Occupational injury and illness statistics: Where does your manufacturing job rank?In December 2003 the U.S. Department of Labor's Bureau of Labor Statistics (BLS) released its 2002 occupational injuries and illnesses data. A total of 4.7 million nonfatal injuries and illnesses were reported in private-industry workplaces during 2002, resulting in a rate of 5.3 cases per 100 equivalent full-time workers. Among goods-producing categories, incidence rates ranged from 4.0 cases per 100 workers in mining to 7.2 cases per 100 workers in manufacturing. These numbers are overall averages of subsets in each major category.
|
|
Emergency preparedness: A critical safety program componentYou're at work and a fire alarm or other emergency warning device sounds. Do you know what to do? Where to go and the appropriate route to get there?
|
|
Gear up for welding |
|
Welding fume health hazardsAccording to the National Institute for Occupational Safety and Health (NIOSH), more than 400,000 U.S. men and women are employed in welding and related occupations. Some studies suggest that these workers are at risk of serious respiratory, neurological, and reproductive effects. More and better data is needed to assess the risks.
|
 |
Safeguarding machines with an ergonomic spin: The importance of human factors in indstrial safety standardsHuman factors contain elements of psychology, engineering, statistics, and observation. Safety codes and standards often are written based on some aspect of human factors, and it may be critical to have a full understanding of the human factors behind the code or standard before applying the same concept to other equipment.
|
|
A breath of fresh air - Taking a look at in-plant filtration systems: Taking a look at in-plant filtration systemsThe article explains how to carry out a facility and process evaluation and discusses the basics of in-plant air filtration system selection.
|
|
Maximizing your scrap's value: Diligence in preparation and tracking pays offThe more uniform and contaminant-free that scrap is when fabricators provide it to recyclers, the more fabricators can benefit. This article addresses the two principles for selling scrap to recyclers: know what you're selling vs. what you're getting paid for, and incorporate sorting & cleaning into your production stream.
|
|
Sell! Sell! Sell!: Developing a profitable exit strategy for you and your companyDevising a strategy for selling your company that fits within your goals and current market conditions is essential
|
 |
Applying the theory of constraints in a structural steel plant: How keeping busy can be a BAD ideaMerely staying busy is not a determinant of success.
|
 |
Surviving an OSHA inspection: What to do if an investigator shows up on your doorstepWeathering an inspection by OSHA is a matter of knowing your operation from top to bottom and being prepared for a visit at all times.
|
|
To e, or not to e?: Hamlet.com? Not quite, but automakers trying to save princely sums via InternetThe idea was to have e-commerce solve everything. Then the thud of a million dot-coms hitting bottom gave people a new perspective. Are automakers still hip on e-commerce? You'd better believe it.
|
 |
Managing innovation in the factory: Turning improvements into intellectual propertyIn many industries, more than three fourths of new products start out as direct requests from customers. How can you find and capitalize on the opportunities hidden in offbeat requests?
|
|
Put your money where your mouse is: How to succeed in e-businessTo decrease your chance of failure in e-business, focus on the business issues first and the technology issues second.
|
 |
Building a better business model: Strategic planning basics for automotive stampers to improve profitJust what is a strategic business model, and how can it be developed and used by an automotive stamping supplier wanting to boost its bottom line?
|
|
Mediating commercial conflictThis article explores some of the aspects of a commercial mediation I performed some years ago. The identities of the participants and the facts of the case have been changed to preserve the participants' privacy and the confidentiality inherent in mediation cases. This case was selected because of the intense emotional feelings that surrounded what should have been a straightforward and rather simple business arrangement. So often it seems that the feelings, emotions, and egos of the participants in a conflict can mean more than the dollars or tangible value involved.
|
|
What price workers' compensation insurance?It's a Catch-22 for many manufacturers. Not having workers' compensation insurance can put them out of business. Paying for workers' compensation insurance can put them out of business. How is a company to survive?
|
|
Workers' compensation—Managing the process |
|
Reflection—Getting the most from experienceLeaders, what have you learned about yourself, your employees, and your company in the past year? What were your business blessings? What did you learn about your leadership style or methods? What do you intend to take into the new year, and what will you leave behind?
|
|
New Year's Resolutions: Making them work all year longWhat are your resolutions for 2004? "I'm going to lose that extra 15 pounds." "I plan to exercise more this year." "I'm going to be more complimentary to my staff." "I'm going to be more patient." Or, did you remember the resolutions you didn't keep last year and ask yourself, "Why make resolutions? I won't keep them once I get back to the daily grind."
|
 |
Taxing situation: New tax incentives aimed at helping out people like metal fabricatorsMost fabricators aren't knowledgeable about tax laws and don't have time to immerse themselves in tax updates. They're too busy on the shop floor.
|
|
US. DOC Offers Export Assistance: Provided by the U.S. Department of Commerce and the International Trade Administration. |
 |
Implementing open-book management: A management philosophy for surviving the global economyToday global competitors are literally willing to work for food. U.S. workers want a car, a home, and a college education for their kids in addition to their meals. Reducing pay and eliminating benefits is not an answer for anything but a lower standard of living. The challenge is not reducing compensation but rather dramatically improving productivity. Making owners out of employees is the ticket to that productivity. Open Book Management is a philosophy—a value system.
|
|
Is Your Welding Lean?Want know how lean manufacturing principles relate to your welding operation? You have to look further than just what is happening in the welding cell.
|
|
Slash maintenance inventory costs: Five steps for managing MRO partsThe quickest boost for most organizations' bottom line is finding opportunities for decreasing costs without sacrificing quality. An area frequently overlooked is the inventory of parts kept for maintenance, repair, and operations (MRO).
|
 |
Inline Process auditing: Moving beyond random samplingImagine this: The line is running smoothly, delivery is tight but on schedule, it is 10 minutes to shift change, and suddenly Art the quality control inspector runs by the office window shouting, "We've got bad parts coming out!" You shut the line down, your production supervisor comes running, Art is grabbing as many parts as he can to start checking, and the operator is thinking, "I should run now and let the second shift deal with it."
|
|
Family business going strong after 100 yearsThe average lifespan of a family-owned business is 24 years, and 60 percent of family-owned businesses do not have a clear succession plan. Tell that to the Peddinghaus Corporation and you might be in for a big "Oh really?" In business for 100 years and with a Peddinghaus still at the helm, the family-owned manufacturer of steel construction industry equipment clearly is a statistical exception.
|
|
Beating 'world' pricing: Nu-Way Industries finds the formula to take on competition from ChinaDuring the depths of the manufacturing slowdown that has cost the fabricated metal products sector nearly 300,000 jobs since 2000, Steven Southwell, president of Des Plaines, Ill.-based Nu-Way Industries Inc., faced a depressing challenge from one of his multinational OEM customers??either meet the ??total cost of acquisition? achieved in China or purchase the part from the Chinese supplier, inventory it, and incorporate it into the family of parts supplied by Nu-Way.
|
|
Ridin' the storm out: ArrayArray
|
 |
Ridin' the storm out Part I: Part I: Lean helps stamper squeeze out “automotive 5 percent”While other automotive suppliers are struggling or going under, Tier II supplier of ride control components Tennessee Stampings established a lean program that merited a regional manufacturs' award and helped them grow 23 percent per year.
|
|
'It's gonna be painful' Metal industry players note little to reassure them in days aheadManufacturers were hurting before September. How do things look now? Well ... they could be better, industry players say.
|
 |
Staying lean in a lean economySlow times call for some desperate measures, but losing sight of a lean approach to manufacturing should not be one of them. Take an opportunity that slow times present to evaluate your business and take appropriate steps towards a lean operation.
|
|
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.
|
 |
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.
|
|
Sick at Work?All employees have days at work when they don't feel well. Usually these days are intermittent and can be attributed to a cold or other illness or job-related stress.
|
 |
10 questions to ask about equipment leasing: Inquire before you signEquipment leasing—an arrangement in which a business pays for the use of equipment but does not own it—is growing in popularity for many reasons. Benefits of leasing include flexibility, convenience, and protection from having to be responsible for equipment obsolescence.
|
|
The Perfect Economic Storm and The 100-Year Flood in Manufacturing—Part 1 |
|
The Perfect Economic Storm and The 100-Year Flood in Manufacturing—Part 2 |
|
Pinpointing future laser welding marketsAficionados of laser welding technology at times must feel a little like telephone vendors beamed back to 1603. They know almost everyone is going to use them in the future, but getting buy-in today can be like hawking loans at 25 percent-lots of interest and few takers.
|
|
March for manufacturingAs the "jobless" recovery continues, the job cleansing of the U.S. manufacturing base tops 2.7 million. These millions now without jobs remain faceless, statistical footnotes to mainstream media reports about how the recession ended in 2001, production is on the rise, and how job losses are singularly attributable to productivity gains. The outsourcing of the American dream for small manufacturers proceeds unabated.
|
|
A 'bout' with the championRep. Don Manzullo speaks about taxes, steel tariffs, health care, and manufacturing's future.
|
|
Goin' Global: How U.S. fabricators can angle in worldwide watersThe U.S. is considered to be the best consumer market in the world. However, competition for this market has increased as more and more countries have cast their rods in the U.S consumer pool.
|
|
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.
|
|
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.
|
|
Tips on Lean Manufacturing: Mastering the stop 'n' go of your shop's work flowMastering the flow of work through your shop is your most important taks if you are attempting Toyota's approach to lean manufacturing.
|
|
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.
|
|
Using technology to implement lean manufacturingLean manufacturing is more than a buzzword. It is key to improving a company's floor performance, customer responsiveness, and, ultimately, its bottom line. Yet few manufacturers truly understand what it takes to implement the concept.
|
|
Looking to the future: Steel supplier designs facility based on regional current, future needsA growing manufacturing base in the Southeast spurred Thompson Steel in the mid-1990s to research what type of equipment to purchase for its new facility in Fountain Inn, S.C. The steel supplier had been shipping coils of slit steel from its plants in Baltimore; Franklin Park, Ill.; and Rome, Ga., almost daily to several customers in the area.
|
 |
Do you see the light?In this article, The FABRICATOR® attempts to shine the light on opportunities for improvement in both the front office and on the shop floor. In this case, the light is on the lights—as well as the heating and ventilating system and other energy-sapping devices.
|
|
Taking a look at performance appraisalsIf you make continuous feedback part of your managerial style, the annual performance appraisal becomes an affirmation of a positive working relationship.
|
|
In Human Terms—The value of engaging the workforceBuilding trust with employees, listening to them, and spending time face-to-face with them helps managers in little critical ways they never may have imagined.
|
 |
Getting the most for your money: 12 financial tips for welding professionalsThese include the importance of contributing to an individual retirement account, retirement programs for the self-employed, tax-exempt investments, $10,000/year gift tax exclusions, charitable contributions, how much money you should keep in checking and savings accounts, liquidity, and diversified portfolios.
|
|
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?
|
|
The future of vocational educationThe death knell is sounding for vocational programs throughout the U.S. Readers who responded "Yes, vocational programs have been cut" to thefabricator.com's recent question regarding the status of vocational programs where they live outnumbered those responding "No, vocational programs are intact" three to one.
|
|
Tuning a piano—making the most of your best resources |
 |
Budget cuts hit welding hard: Extraordinary effort is critical to welding programs’ survival |
|
Shedding light on negativity—Part 1 |
|
Shedding light on negativity—Part 2 |
 |
Flatness in coil processing operations: New turns in the leveling processMost flat-rolled coil processing operations use some sort of roller leveling technology. Operations people understand what these machines can do to improve the quality of the product they produce. In the competitive marketplace, customers demand and get more that just flat sheets or slit coils.
|
 |
Pairing a servo feed with a pull-through straightener: Applications for noncosmetic stamped partsThis article explores the possibility that servo feeds can be used with pull-through straighteners as opposed to a conventional feed line that uses a powered straightener. Using the servo-PTS (pull-through straightener) can save money on equipment and material. The only limitation may be marking the material so noncosmetic applications are recommended.
|
|
The basics of uncoiling: A review of standard equipmentA review of the basic components of a coil handling system which covers servo drive roll feeds, cradles and reels, straighteners and combination units.
|
|
Examining slit coil handling and packaging: Choosing a system for increased productivityWhile it is common knowledge that slit coil handling and packaging often limit the productivity of even the most modern, high–speed coil slitting line, coil processors generally spend too little time examining the effectiveness of these operations.
|
 |
New Features in Coil-to-Coil Slitters: Adapting to the changing coil industry with technologyYears ago it was customary for coil processors to have dedicated slitting lines for specific materials and gauges. Today's larger, stronger, and thinner-gauge coils, however, require service centers to be able to process many materials and gauges on the same machine.
|
 |
High-Speed Feeding Techniques - Reviewing the Facotrs that Affect Process SpeedsGripper or roll-type feeds operate on the principle of feeding force, which is a product of the coefficient of friction between the grippers or feed rolls and the material being fed. Reviewing each force as a factor of the feeding equipment or feeding conditions helps in evaluating the feeding process.
|
|
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.
|
 |
Handling the RushThink delicate: an antique vase, velvet gloves, the sweet sound of string music.Then imagine a typical stamping operation: bam-bam, metal on metal, all day long.
|
 |
Maximizing a coil fed press: Variables that influence production speed, setupCoil-fed stamping presses are nothing new, but coil feeding processes have changed a lot since the days when press feeders were driven mechanically by crank motion. Influencing these processes are differences between transfer and progressive tooling.
|
|
Appliancemaker reduces downtime with stamping press feed system: Inconsistent feeds caused die jams, inconsistent partsThe Whirlpool Co. builds refrigerators at its facility in Fort Smith, Ark. The company stamps the appliance parts—large and small, galvanized, cold-rolled, and aluminum—on approximately 35 presses. The majority of its stamping presses are straight-side machines, although some are open-back inclinable (OBI), and a few are hydraulic.
|
 |
Contract stamper increases die life and draw die productivity: Link-drive presses, value-added services, and employee initiative keep the company competitive |
 |
Metal stamping and electromagnetic forming: New process improves material formability, reduces wrinklingThis article describes the development of electromagnetic forming (EMF) and how EMF works.
|
|
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.
|
|
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.
|
|
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.
|
 |
Equipping Your Press With the Right Tonnage MonitorThis article explains why it's useful to monitor press tonnage, the types of tonnage monitors available, the choices for mounting load sensors, calibrating a monitor, and options available for tonnage monitors.
|
 |
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.
|
|
Increasing stamping press productivity in the appliance industry: Advances in press technology and materials leave their markAn appliance plant with 80 to 100 presses in opeation is likely to buy new presses regularly. Under these circumstances, it makes good sense to pursue aggressive productivity goals inch by inch through steady advances in such prosaic concerns as machiner ergonomics, prventive maintenance, tooling efficiency, and material quality.
|
 |
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.
|
 |
Truckin' along through a stamping plant: Redesigned truck cab leads to new plant, processesInternational Truck and Engine Corporation's Springfield, Ohio, plant recently undertook the challenge of building a high-performance truck with the dimensional tolerances that meet today's quality standards within a cost structure that would allow it to remain competitive. This new product launch was the first of its kind for the company in more than 20 years.
|
|
Hydraulic forming takes a front seat: How an automotive supplier improved quality characteristics on seat adjuster channelsFor about 50 years roll forming was the process of choice for making seat track channels at Dura Automotive Seat Systems, Stockton, Ill. While the process was high-speed, low-maintenance, and flexible, it also caused channel end flare, twist, and bow.
|
|
Taking the heat, keeping the current: Heat sinks provide thermal conductivity, electrical isolation |
|
Virtual tryout: Simulation software simplifies progressive die troubleshooting |
|
What's driving your press?Mechanical presses are challenged to provide high-speed production with a greater number of hits per minute, smaller batch runs, and quicker die changes.
|
 |
Hydraulic presses make their mark |
|
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.
|
 |
High-tech presses: Servo technology meets mechanical presses |
 |
Finding and creating value in your stamping operation: How to analyze your plant to improve profitabilityA different breed of competitor has emerged recently in the stamping industry to challenge traditional thinking. These competitors are companies that focus on time as a basic measurement, giving them the advantages of flexibility, innovation, responsiveness, and low costs. They know how to make money in stamping operations and take business away from less astute competitors.
|
 |
Using Monitoring Systems to Improve Stamping 'Batting Average'What do baseball players, weather forecasters, and typical stamping plants have in common? Most are less than 60 percent effective.
|
|
Dangerous curves: Jaguar successfully mass-produces the industry’s first aluminum body structure |
|
Spraying it right: Containing and controlling lubricants |
|
Ridin' the storm out: ArrayArray
|
|
Do you use checking jigs and fixtures?: An ounce of prevention is worth a pound of cureHow do you check tube fabrications to ensure they meet quality standards? Do you ship parts without checking them and hope that the next time the phone rings it isn't a prelude to a tirade from a disgruntled customer? Or do you check finished parts only to realize that your scrap rate is too high and wish you had checked them at earlier stages of the manufacturing process?
|
|
The problem with quality: A closer look at quality ratingsIn May, automotive quality gurus J.D. Power & Associates released the results of its 2003 Initial Quality Study (IQS). As is the case every year, the winners will trumpet their scores while the losers will promise improvement. A closer look at the numbers, however, reveals some interesting observations.
|
|
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.
|
|
Achieving straight-side capabilities in a gap-frame press: New developments in motion and frame technologyRecent changes in tooling technologies, material specifications, part quality requirements, and inventory levels have driven the demand for new developments in the way a mechanical press operates. This article discusses how link motion and bridge-frame structures help stampers. This includes a description of what link motion is and how it works, and how bridge frame presses affect frame deflection.
|
|
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
|
|
Designing progressive dies: Reviewing the basics of progressive toolingDecisions and compromises must be made when designing progressive dies to produce a part. Knowing ahead of time what this process entails just might help you.
|
 |
Sharpening for a longer life: Maintaining the cutting edge on punch and die componentsRoutine maintenance—grinding, using surface treatments, sharpening ejector pins, and minimizing potential grinding damage—can extend tool life and save you a lot of headaches.
|
|
Gettin' down with downtime: Reducing unprofitable die changeover timeReducing the time it takes to change dies it important to all stampers, especially for custom stampers that run small-quantity jobs. This article summarizes the ways in which automation has helped in this process and then covers two die change methods that are used in a quick change system: the standardized clamping system and the V-notch, or key, system.
|
|
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.
|
 |
Resisting cracking, deformation, and premature wear: Powder metallurgical steels provide an alternative to conventional tool steelsWant to know how powder metallurgical tool steels are produced and how their properties provide the material's toughness and wear resistance? Read on.
|
|
Rising expectations spark new approach to draw die development: Reconciling demands for increased quality at lower costsA recently formulated approach to draw die development incorporates simultaneous engineering to identify and address potential problems before dies are built.
|
|
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.
|
|
Cutting die-related costs: Where to look to save moneyDemands for cheaper, better, and faster tooling for stampings and the pace of business continue to escalate. This trend is not going to reverse itself.
|
|
Tooling tricks of the trade: A few tips for extending die life |
|
Taking an integrated build approach to stamping tool tryoutMarket pressures to reduce tooling costs are pressing the tool and die industry to seek lower-cost tooling solutions. This column discusses different build approaches and the merits of an integrated build for trying out stamping dies (and molds) as part of the manufacturing validation process.
|
|
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.
|
|
Die width selection |
|
Choosing the proper steel to minimize abrasive adhesive tool wearThe most disruptive type of failure in any tooling application is when the tool cracks. To prevent this type of failure in cold-work applications, it's important to select the correct steel.
|
|
Controlling bend anglesBend angles are among the most frustrating geometric features to control in metal stamping. This is due primarily to two factors – the inconsistency of the mechanical properties in the metal being bent and the die design.
|
|
Selecting a pressure system for a stamping dieAuthor's Note: Before I begin, I would like to take this opportunity to express my sincere thanks to thefabricator.com's readers. I hope you have enjoyed the stamping articles, and I am excited about writing for 2004. I also would like to wish all of you a great holiday season as well as a prosperous and successful year. Best holiday wishes!Art
|
 |
Rolling bolsters bolster productivityTo thrive and experience growth and healthy profits, a stamping company must have systems in place that allow flexible manufacturing and minimize press downtime. Changing from one job to the next in the least amount of time possible is one of the primary factors impacting productivity and a company's ability to adjust to the changing needs of customers quickly and efficiently.
|
|
Selecting a stamping die pressure system, Part II |
|
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.
|
 |
Bending tube with an all-electric machine: Characteristics and capabilitiesThis article discusses the ins and outs of all-electric tube bending machines, discussing the challenges, performance characteristics, and typical options of all-electric benders.
|
|
Magnetic pulse welding for tubular applications: Discovering new technology for welding conductive materialsA review of how magnetic pulse welding works, in what applications it can be used, and what considerations users must take to perform it properly.
|
|
Automating for the future: Tube bending tool manufacturer uses software to speed production timeIf you need to cut production time, you might glean a few tips from a little job shop in Ohio that has made the most of its software.
|
 |
Cutting tube in a recut operation: How to decide on a method and equipmentThis piece, which originally appeared in TPJ-The Tube & Pipe Journal in 1997, explains how to decide whether to cut tubing on the production line or cut it later in a recut operation. Discusses various types of recutting equipment and focuses on the dual-blade shear cutting method.
|
|
The growing use of orbital tube welding: Quality, repeatability, and documentation drive the technologyAlthough orbital tube welding has been used in aerospace, semiconductor, and other high-purity applications for a long time, general industrial markets just now are beginning to view it as a viable and economical option for joining stainless steel tubing.
|
|
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.
|
 |
Selecting the right temporary coating: Choices abound for tube and pipe applicationsTube and pipe manufacturers should consider carefully environmental laws, cost, quality, and the cost of a coating line before deciding on a temporary coating for their products.
|
|
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.
|
 |
Coating fabricating toolingTube fabricators all over the country are starting to see some major benefits from new coating technology. Many coatings-both those that are time-proven and new ones just hitting the market-can provide many benefits for many tube fabrication processes, including extended tooling life, better finished parts, and less stress on machinery.
|
|
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.
|
 |
Waste not, want not: ArrayArray
|
|
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.
|
|
The little-known life of the scarfing tool: Focusing on a small device to see the bigger pictureWho cares about scarfing tools? There are more important things in life. When the beauty pageant contestant is asked what problem she would like to solve, she's more likely to answer "I'd like to establish world peace" than "I wish I could find ways to help scarfing tools last longer."
|
|
The wrinkle-wiper for tube bends: How to choose and use wiper diesA wiper die is a piece of tooling used in tube bending that helps keep the bend from wrinkling. While there are many reasons and ways to use a wiper die in a tube bending maching, you should also know what types are available, their differences, and how to choose the right one for your application.
|
|
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.
|
|
Using a gel-type tube lube: Manufacturer decreases waste, improves lubrication |
 |
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.
|
|
Troubleshooting compression bendingYou can achieve nearly trouble-free bending by being aware of the causes of typical compression bending problems and by correctly operating and maintaining the compression bender.
|
|
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.
|
|
Choosing the right robotic weld cell for your operationYour company's first robot may cause more trouble than expected. This doesn't mean that the robot will not work, but it is a piece of
|
 |
Low-tech system mechanizes pipe welding: Backing device allows GMAW on open rootWelding technology has changed dramatically over the last few decades. Although skilled welders always will be needed in manufacturing, mechanical welding devices can provide improvements over manual welding in terms of repeatability and throughput.
|
 |
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.
|
|
Maintaining and troubleshooting HF welders: A common-sense approach for vacuum tube and solid-state machinesThe basic steps of general preventive maintenance and troubleshooting for both vacuum tube and solid-state high frequency (HF) welders should assist in keeping welders online and producing pipe or tube.
|
|
Tooling, the key for mill productionThis article discusses three main criteria that govern tube mill tooling—design, materials used in their construction, and alignment of tooling on the mill. Discusses advancements in design due to CAD technology; experimental use of ceramic and plastic materials for making tooling; and the use of subplates and interchangeable components to ease tube mill alignment.
|
|
Achieving faster, more efficient tube mill changeoversTube mill changeovers involve more than just tooling. Several variables
|
 |
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.
|
|
Laser welding of stainless pressure tubesNot all laser welded tubes are created equal. Know what to look for in the final product to ensure that you're buying quality and not just an imposter.
|
|
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.
|
|
Taking the troubles out of tube mill tooling: Preventing and solving some common problemsThis article discusses the prevention of problems associated with tube mill tooling, touching on maintaining tooling, as well as troubleshooting common problems that may arise during the tube production process.
|
 |
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.
|
|
Do your tubes seam good enough? Using eddy current testing to make sureEddy current testing offers several features that makers of welded tube may find to their liking—in particular, high throughput speeds and sensitive flaw detection.
|
|
Inline gauge control in welded tube production: Reducing conversion lossesReducing scrap when converting strip to finished tube is a huge step in bettering your bottom line.
|
 |
Solving the mysteries of the fin pass—Part 2Editor's Note: This article is the second part of a two-part series about fin passes. Part I, which appeared in the March issue, discussed their location, what they do, and how they do it. Part II focuses on troubleshooting.
|
|
Roll form tooling tryout and troubleshooting: Taking a five-step approachThe secret to developing successful roll tooling—whether for tube production or roll forming—and achieving maximum roll integrity is a simple but often overlooked notion: a comprehensive approach.
|
|
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.
|
 |
Structural adhesives form strong bond with signage: 10 questions about joining metal to metal, metal to plasticsSign-makers have long sought a way to improve durability and aesthetics and reduce the labor-intensive steps associated with welding, taping, and fastening. Today's adhesives can structurally bond metals to plastics with unique design, production and costs benefits, thereby making them an alternative to welding and mechanical fasteners for sign industry fabrication.
|
|
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.
|
|
Choosing a GMAW machine for occasional aluminum welding |
|
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.
|
|
It's all about precision, craftsmanship: Shop makes commitment to solid welding practicesA case study looking at how Superior Joining Technologies Inc. got into the microwelding business, the welding equipment they use, how the meet customer requirements, and how they use a solid foundation in welding to keep up with today's stringent requirements.
|
 |
Gun Control: GTAW torch design innovations enhance productivity, qualityThis article discusses improvements to the GTAW torch that should enhance the productivity and quality of welding operations. It specifically discusses the welding gun's affect on ergonomics and cooling capacity.
|
|
Joining aluminum with GTAW: Advice for the noviceAluminum is a real challenge to weld, especially for beginners. A knowledge of the gas tungsten arc welding equipment that is available to do the job as well as required accessories, preparation tips, and proper techniques is a good thing to have before jumping in.
|
|
The fundamentals of gas tungsten arc welding: Preparation, consumables, and equipment necessary for the processLearning the fundamentals of the GTAW process will increase the welder's ability to produce quality weldments. Knowing the correct consumables, equipment, and preweld preparation necessary will help the welder troubleshoot welding problems.
|
|
Mastering the art of welding—it's all about proper technique |
|
The history of welding according to MartyThis is a welding history synopsis, as seen by me. If you are a history or English professor, you might want to stop reading at this point; it ain't gonna be pretty.
|
 |
Getting the best results in gas-shielded FCAW: Filler metals play a crucial role in the process |
 |
Whale watching: A doctor's love of whales leads to a complex welding projectMetal artist James Berry constructed a large whale display by making healthy use of Gas Metal Arc Welding. Here's how he did it, and why.
|
|
Reviving the past: Welding students restore ironwork to Victorian-era YMCA building |
 |
Riding on the cusp of something great: When Colorado artist's career hits plateaus, he climbs themKevin Robb's sculptures seem to defy gravity, arrest time, encroach space. Each sculpture is a moment freeze-framed; each element seems to be impossibly suspended.
|
|
Art From the Forge: Finding new sources for inspirationThose of you who are busy fulfilling commissions for gates, fences, staircases, and the myriad items that keep food on the table might want to look at artwork created by people whose backgrounds are based in the arts. Metalworkers often are so tuned to traditional designs that they are unaware of a swelling modern movement that could generate new ideas, new visions, and new clients.
|
 |
Washington women weld at the 'Y': Students learn by doing in their community |
|
Metal Art Takes on the Fireplace: Jim Truett’s custom fireplace screens are both functional and beautifulMetal art takes on many forms, from wall hangings to picture frames to fireplace screens. Just ask Jim Truett, a district sales manager for Miller Electric Mfg. Co. by day and artist in his spare time from his Huntsville, Utah, home.
|
|
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.
|
|
Robotic arc welding gets smart in real time: Immediacy of information can benefit shop floorsWhether you're dealing with low part counts or wild welding variables or the challenges of just-in-time production, monitoring software can help smooth your operation.
|
|
Automated welding for job shopsA robotic weldingsystem represents a significant capital investment for a job shop.
|
|
Welding aluminum tailored blanks with Nd:YAG lasers for automotive applicationsThe increased average power at the workpiece delivered by a 4-kilowatt, continuous-wave Nd:YAG laser source can be used for tailored blank welding of aluminum alloys
|
|
Setting realistic goals for robotic welding projectsExpecting a robot to solve all of your production problems can inflict the cruel irony of ceating more. If you want your robots to speed up your operation, know what they can and can't do from the start.
|
|
Is robotic welding right for you?: Making an informed decisionThis article examines robotic welding and discusses the considerations behind choosing to use (or not use) welding robots. It answers the questions what comprises a robotic welding installation, what costs are associated, and what industries are best suited for robotic welding.
|
 |
Welding exhaust system components: Laser technology may aid this traditionally high-volume applicationIn the field of automobile exhaust systems, such components as manifolds, pipes, catalytic converters, and mufflers are joined either by the car manufacturer or by a subcontractor to form a subassembly ready for attachment.
|
|
Robots and dials and knobs—oh my!: GMAW power sources have evolved over timeIn the late 1950s, the U.S. Navy wanted to find a way to join heavy aluminum structural sections used to fabricate motor torpedo boat hulls.
|
|
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.
|
|
Selecting equipment for a robotic welding workcellSo you've decided to automate your welding process. Now it's time to select the equipment that performs the robotic welding. It's critical to take care choosing the appropriate equipment and an integration partner.
|
|
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.
|
|
Gas-shielded cored wires find their niche: Suitable applications for flux-cored and metal-cored electrodesGas-shielded flux-cored and metal-cored wires are growing in popularity because the wires are fabricated and can be applied to many applications.
|
|
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
|
|
Don't be a hot dog with heating heads: Tips for safe useSome call them rosebuds, others call them multiflame heating heads, and a few call them heat sticks. No matter what you call torch attachments, this article is a frank discussion about these tools that use oxygen and a fuel gas to make a lot of heat quickly. When used properly, they can make quick work of many heating jobs.
|
 |
Which wire do you require?: How to select a gas-shielded welding electrodeAre you looking for ways to improve quality, raise productivity, and save costs in your current welding operations? If you haven't examined the various electrode choices, you could be missing an opportunity to take your production welding to the next level.
|
|
Four factors to consider when purchasing a grinder: You get what you pay forCost often is a deciding factor when you purchase a grinder. However, the saying "you get what you pay for" can be true when you're talking about tools. The price tag alone doesn't always reflect some of the more important factors--performance level, cost to operate, and tool life--that make a grinder worth its cost.
|
 |
Three optional techniques for beveling: Understanding the advantages and drawbacks of eachMany fabricators use standard plasma cutters and abrasives to create beveled edges. Along with these traditional methods, welders also have the option of using three alternative beveling techniques: punch and nibble, peeling and shearing, and milling and routing. Each has advantages and drawbacks.
|
|
Supporting the defense: Manufacturer uses direct diode laser to weld missile canisters |
|
Producing side-impact profiles: Automotive body part combines roll forming, punching, laser weldingThe ramming machine bores into the side of the new automobile at a speed of 50 kilometers (31 miles) per hour. Within a fraction of a second, sensors situated all over the test dummy signal details of the stress load. Shortly afterward the overall results of the Euro-NCAP crash test will appear in all the specialized automobile magazines.
|
 |
Revving up weld quality: Ford Development Center uses RW system to reduce costs, improve quality |
|
The Brakes- Press Brakes and You -- How to get the most out of your press brakeProblems with your press brake imperil what could be the most valuable machine you have. Take pains to ensure the health of this valuable piece of equipment.
|
|
Brake Line: Press Brakes and More: Planning to cut corners on safety?Press brake safety is a common sense issue.
|
|
Mobilizing equipment-saving time and talentIt's hard to believe that machines such as press brakes and hardware setting equipment can move around on wheels or be moved by forklift and still function correctly. But I can tell you, from experience, that it is true and can be done.
|
|
The Brakes: Press Brakes and You -- Whose business is safety? Everybody'sWhat sort of safety measures needed in your shop depends somewhat on your equipment, but making your press brake a safe piece of equipment is largely a matter of old-fashioned common sense.
|
|
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.
|
 |
Leaping the hurdles to press brake automationUnderstanding the obstacles to automating press brakes requires an analysis of the bending process.
|
|
Making your own punch and diesHow many times have you looked through huge piles of blueprints for a prototype part or short-run job and thought, "If only I had that tool, this job would be a piece of cake?"
|
|
Press brakes: the quest for a happy ending: Manufacturers, users hope technology is the ticketScreen some press brake owners and manufacturers these days, and it's like they're all reading from the same script:
|
 |
New PC-based controls open path to better press brake utilization: Control improvements simplify operator usePress brake forming always has been a labor-intensive process. Shrinking lead-times and smaller lot sizes demand more frequent setups, which cut into productive output hours and put more pressure on manufacturing efficiencies. Fabricators need to find ways to reduce machine downtime for setup and operator adjustments.
|
|
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.
|
 |
Repair Brazing: Fixing Faulty Jobs and worn-out componentsBrazing has myriad uses for shop repairs. Knowing what seperates a proper brazing job from a poop one can save you alot of headaches and produce some slick results in the process.
|
 |
The challenges of laser cutting: Overcoming some common obstaclesLasers can be used to process expensive alloys as well as traditional materials such as stainless steel. However, knowing the strengths and weaknesses of laser processing is the key to determining whether or not a laser is the right choice for cutting.
|
|
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.
|
|
Monitoring laser beam performance: How beam focusability helps evaluate beam quality onlineThis article discusses online laser beam monitoring and its alternatives, with emphasis on beam quality and focusability.
|
|
Job shop reduces costs, improves laser's output: Laser regulator minimizes gas contaminationToday's job shop market is characterized by unrelenting competitive pressure for laser processing services. Job shops are expanding into niche services such as multiaxis laser processing and thick plate applications to differentiate themselves from their competitors. Others are performing additional services such as forming, welding, painting, and assembly to add value.
|
|
The business of lasersAs we all know, the laser industry has seen easier times. Economic and market pressures have changed the competitive landscape for laser cutting equipment, and the changes are likely to continue. Both lasermakers and laser users need to adapt to the changes in the laser market, and the companies that recognize and adapt first are likely to be those that succeed.
|
|
Cutting through five myths about modern lasers: The truth behind laser cutting technologyWhether you're operating a 10-year-old laser machine or evaluating the purchase of a new one, staying up-to-date on current laser cutting technology and techniques can be the key to maintaining a competitive edge.
|
|
Laser cell system gives job shop the home field advantageContract manufacturer CGI Automated Manufacturing Inc., Cicero, Ill., fabricates parts as an outsource resource for vertical manufacturers. The company started out as a stamping operation, then added other fabrication technologies, including welding, press brake forming, drilling, punching, rolling, shearing, and cutting.
|
|
A breath of fresh air: ArrayArray
|
Facebook
Twitter
LinkedIn