FluidForming perforated sheet metal? Yes!

Recently, FluidForming was approached with a new challenge: form a part that is perforated prior to forming. Fundamentally, that is not possible, because the process needs a ‘solid’ surface area that allows the water (our forming fluid) to pressurize one side and force it into the tool. In this case, it wasn’t economical to cut the holes into the plate after forming it and the perforated surface was in an area where minimum elongation was expected. Hence, the decision was made to pursue an approach using a sacrificial, minimum thickness and minimum cost metal sheet.

See the result and more in the FluidForming Perforated Sheet Metal white paper.

How to troubleshoot plasma cut quality

Like any cutting process, there are a lot of variables that affect plasma cut quality. Some of these variables include:

- Torch Type
- Torch Alignment
- Condition of consumables
- Arc Voltage, or cutting height

...and more.

Most of these variables are interdependent, meaning that if you change one variable, it will affect the others. Figuring out how to fix cut quality issues can be difficult, so the following information was assembled to provide the usual solutions to some typical cut quality problems.

Read the entire ESAB Plasma Cutting white paper.

October 2013 - Discovering the truth about robots is essential. Separating fact from fiction and science fiction, while looking at the truth about effectiveness, efficiency, and impact of robotics on employment is addressed in a careful analysis regarding the changing role of robots in the plant and warehouse floor.

The Truth About Robotics white paper examines: 

• Robots Taking Over the Plant Floor
• Histrionics Versus History
• Scenario Planning: Robots Shift with Job Market
• Role of Manufacturing Optimism
• Robots Create More Jobs
• Stressed Workforce Equals More Injuries: Robotics Solve Challenges of Increasing Demands on Workforce
• Cost of Litigation Destroys Profitability: Robots Don't Litigate
• Safety and Quality Should be Synonymous
• Estimated Cost of Occupational Injuries and Illnesses and Estimated Impact on a Company's Profitability Worksheet
• Eliminating Waste and Measurement with Robotic Industrial Solutions
• The Trouble with Traditional AGVs...High Risk at Too High a Price
• Cultural Acceptance of Robotic Technology vs. Traditional AGVs
• Flexibility and Scalability Proves Advantage of Robots vs. Traditional AGVs
• Facility Modifications Rule Out the Value of  Traditional AGVs
• Nothing to Fear From Robots

Download the entire The Truth About Robotics white paper.

Industrial strength Magnetic Separators play a very important role in manufacturing facilities across the world. If handled properly, they are a safe, efficient way of removing unwanted ferrous contamination from a valuable product. If not handled properly, injuries have ranged from the minor pinched finger to the more serious crushed hand or the loss of extremities.

For these reasons, plant managers are putting more emphasis on Magnet Safety Training for the protection of their workers.

MAGNET SAFETY
1. Awareness: Make employees aware that there are strong, potentially dangerous magnets in a given area of the plant. This is accomplished by providing “strong magnet” warnings/labels on the magnets themselves and also in the area that the magnets are installed.
2. Proper Magnet Handling: Assure that no two magnets come in close proximity to one another when handling, and prevent magnets from coming in close proximity to carbon steel or other ferrous (magnetic) metals. By doing so, you will limit the danger to the person handling the magnets.
3. Transportation and Storage: Before transporting a magnet, pre-inspect the route for any potential carbon steel dangers. Wood, plastic or other non-ferrous containers can be used to create barriers around the magnet for safe transportation or storage. Although the magnetic field will pass through these non-ferrous (non-magnetic) materials, they will decrease the holding strength by creating barriers between the magnet and the carbon steel.
4. Medical Devices: Some medical devices (such as pacemakers) can be adversely affected by strong magnetic fields. Employees should contact their physician and the device manufacturer to determine a safe distance between the worker and the magnet.
5. Credit Cards and Electronic Devices: Keep electronic devices, credit cards, computer disks, and other magnetic storage devices away from magnets. Exposure to the magnetic field may result in malfunction or permanent damage to such items.

Read the entire Magnet Saftey white paper from Eriez.

How to select a gas supply system for a thermal cutting machine?

Selecting the best type of gas supply system for a CNC shape cutting machine will depend primarily on how much gas you will use, but there are some other factors that might affect your decision also.

Topics covered:
Cylinders, Liquid Tanks, or Bulk Tanks?
Gas Consumption
Advantages & Disadvantages of High Pressure Cylinders, Portable Liquid Tanks, and Bulk Cryogenic Systems

Read the entire ESAB Cutting Systems white paper.

Filtering Grinder Coolant Leads to Better Blades

Whether a knife maker is creating a high-end chef’s knife that retails for hundreds of dollars or a discount pocketknife, the manufacturer needs machine tools to grind the blade into a fine edge. The grinding process, however, creates swarf -- or flecks of metal -- that compromise the operation of machinery and the treatment of fluids used. Also, the coolant can help maintain optimum machining temperature during the grinding process. Exposure to high heat would undo the tempering process that makes steel less brittle.

Knife makers need to be mindful of the grinding process because it represents an opportunity to better manage costs, improve productivity and mitigate manufacturing’s environmental impact. Losma creates industrial air and fluid filtration systems, which are intrinsic to operating manufacturing equipment under ideal conditions. As robotics, lasers and precision instruments guide manufacturing, it is paramount to have the equipment operating at its peak. In the case of grinding knives, it means keeping the equipment cool and clean. Under these circumstances, the grinders require lower levels of maintenance and the knives produced have fewer defects. Grinders require a system to collect swarf consisting of a filter made with non-disposable or disposable type media and possibly a magnetic separator pre-filter to maintain the purity of the coolant and keep machines from overheating. Without the filters, lubricating and cooling liquids would need to be replaced, leading to higher material and waste disposal costs. Manufacturers also must consider the efficient use of space, since inefficient coolant set-ups can curtail the number of grinders available to work.

Read the entire Losma - Filtering Grinder Coolant Leads to Better Blades.