What is Slag Grinding?

Slag is defined a type of sand that is traditionally derived from steel. It is a rough, stony-like waste product that is created during smelting or in this case from deburring. After a grinder deburrs sheet metal, the parts that chip off are known as slag. Slag grinding removes all heavy slag quickly and effectively, using rotating brushes that work in the opposite direction of the sheet metal being fed in order to grind and basically sand down the unfinished material. These machines use a series of belts to grind and brush through even the heaviest dross accumulations.

HOW TO GET RID OF SLAG FROM A FLAME CUTTER

Although some metal workers are fine hammering all the slag off of a freshly cut part, it can be a serious pain to work with. The slag grinder from Timesavers is the answer to this nuisance - allowing for slag grinding followed by a good finishing brush.

Slags are a serious headache to remove after cutting metal - think about the time and cost savings with a slag grinder!

The Hammerhead slag grinder

In a newer way to get rid of the “slag”, Timesavers has introduced its Hammerhead Slag Grinder. The innovative approach to grinding metal involves tiny pins that rotate in the opposite direction of the metal being fed into the machine, which allows for the pins to hit and remove any excess metal that does not belong to the main part. It produces a solid, speed-efficient finish, and gives a greater leg up on finishing competition.

For more information, please email info@carlsonfab.com. Also check out Timesavers’ Hammerhead Slag Grinding, Timesavers 1200 Series Slag Grinder or look at Timesavers Deburring for more.

The difference between 5-axis and 3-axis machining

Mitsubishi’s 5-Axis CO2 Laser: VZ20-Series

In most production processes, machining is the largest value-add. Machining involves the removal of excess raw materials in other to produce high-quality parts by water jet cutting or by laser cutting.

In the years past, people carry out this machining operation by using 3-axis machining tools, but in recent years due to technological advancement and increased use of digitally controlled (CNC) people are now subscribing to the more modernized 5-axis machine.

In this article, we will look at what each of the machines entails and the significant difference between the 3-axis and the 5-axis machine.

3 Axis Machine vs 5 Axis CNC Machining

A 5-axis machine keeps the same 3 (X, Y, Z) axis’s but instead adds both the “A” and “B” axis (shown above).

1. Conventionally, materials were fed and worked on three axes (X, Y and Z).

   Traditional laser cutting machines removed material in three fundamental directions, similar to the Cartesian coordinates. Being the mode of operation of the 3-axis machine, 3-axis movement was and still is suitable for parts that have little depth. However, the 3-axis technique cannot handle deeper parts and ones that have narrow cavities because it can be a tasking process to complete on a 3-axis machine.

   On the other hand, 5-axis machines, as its name implies, move in five directions which include three linear X, Y and Z axes with an additional two axes (A and B) around which the tool rotates. This means that every material feed into the machine can be approached in all five directions.  5-axis machining is recommended for deeper parts and more hardened materials, and can guarantee an extremely accurate result. This precision can be attributed to its shorter machining tools, faster tool speed and a reduced vibration tool.
   
   
   

2. A 3-axis machine produces a cusp when a curved material is feed into it.

   This occurs because the machine has a ball-nose endmill (corner radius). A cusp is formed due to a cross-feed between the material and the machine. In a 5-axis machine, the possibility of cusp formation is reduced, because the two extra rotational axes are used to tilt the tool, thereby reducing the chances of cusp formation.

3. A 5–axis machine delivers quality surface finishes with impressive speed.

   This is due in part to the fact that the machinery adopts flat and radiused-corner endmills. The additional axes are used to adjust the rotation and tilt about the surface normal on the workpiece. With greater axes, the machine can become more versatile, and will save the machinist time from having to make continuous adjustments. However, this all comes at a cost, as the greater number of axes will make programming more tricky, so it will require more expertise in operators who are hired for the job, which may bring up costs.

4. In recent years, more innovations in both hardware and software have been developed for complete computer-based control of the tools used by 5–axis machines.

   With the aid of digital controls, there are more efficient ways to handle numerous materials and curved surfaces, thereby enabling production with a high degree of accuracy. Also, with the help of computer-aided manufacturing (CAM), the machining process can be fully or partially automated. 5-axis laser cutting can be seen at the forefront of these innovations.

Other advantages of the 5-axis machining technology include:

With faster machines come a faster need for more advanced CNC controls and automation software.

• faster machining speed

• ability to manufacture Larger-sized parts

• higher yields

• lesser downtime for switching between tooling.

Even though 5 axis machine takes longer preparation and completion/turnaround time, it becomes clear that from the above comparisons that every manufacturer should move with technology by embracing the 5-axis machine, to increase their efficiency and overall level of production.

If interested in learning more about 5-axis machines (particularly laser cutting ones), please see our 5-Axis Co2 Laser Cutting Machines by Mitsubishi for more information.

Also See:

• 5-AXIS CO2 LASER CUTTING

• FIBER LASER CUTTING

Electric Press Brakes Vs. Hydraulic Press Brakes

Press Brakes are changing

When a company’s operations are trying to replace old press brakes of their fabrication business, there is always confusion about what press brake to buy. The reason for this confusion is not far-fetched; it is because of the varying technological advancements in press brakes that exist in our market today.

 Currently, there are electric, hybrid, and traditional hydraulic press brakes. Each of these type of brakes has their pros and cons which, if looked at critically, can help you get the press brake that suits your needs perfectly. In this piece, we will focus more on the standard electric brake vs hydraulic press brake.

ELECTRIC VS HYDRAULIC PRESS BRAKES

1. POWER CONSUMPTION AND EFFICIENCY:

Experts say that electric press brakes use about two times the electrical energy as hydraulic brakes do to deliver the same tonnage. However, the hydraulic motors, pumps, and oil used by hydraulic press brake for its operation keep the machine constantly running even when it is idle. Therefore, electric brakes are more efficient and are considered to consume less power because the motor is used only during bending and turns off while the machine is on idle.

2. COST:

Maintenance of hydraulic brakes such as changing of oil and filter, fixing of seal and line leaks, etc. make it expensive to use hydraulic press brakes. As well as this, due the variable viscosity of the oil used by the hydraulic press, the angle you get at the beginning of the day may differ from what you get at the close of day. This can result in more scrap being developed by the machine, as more trials are necessary for the same bend. Also, the continuous energy consumed by the gear pump during the machine’s idle time will add to the cost of using hydraulic press brakes. In order to be more efficient, some people install energy-saving enhancements, such as timers and variable displacement pumps. These halt the main motor during the idle time to reduce costs, and are an addition that should to be put into consideration when buying a hydraulic brake.

3. SPEED:

Hydraulic press machines have a faster approach speed compared to electric press but have slower ram acceleration and deceleration into positioning because of the oil-powered motor. Hence, the Electric press has a quicker output as it has a higher bending speed.

4. ENVIRONMENTAL POLLUTION:

We already stated the fact that hydraulic pumps work continuously even when the machine is turned off. If you’re looking for fuel efficiency and cleaner energy, hydraulic pumps would not be the best option here. As well as this, for noise pollution, the hydraulic press will make noise all day as long as it is turned on. Electric presses are silent when they are not in use, and the only sound you hear when they are in use is that of the spinning ball screw. For immediate environmental concerns, hydraulic presses (while not often) can also cause oil spillages in the fabricator shop – which can have detrimental effects to the local community. These features, coupled with the less power consumed by Electric press brakes, make them considered to be more eco-friendly than the traditional hydraulic press brakes.

5. ACCURACY:

Electric press brakes have higher precision than hydraulic press brakes. Expert says that electric press brakes can offer up to an accuracy of 0.000079 inches or 1 micron, while hydraulic press brake can reach an accuracy of 0.0004 inches (10.16 microns). For the most accuracy in the game, check out Mitsubishi’s BB Series Diamond Electric Press Brakes.

The advantage of Hybrid Motors

Hybrids also use hydraulics but instead without gear pumps. They typically use a servo electric drive that controls the flow to the cylinders. On electric press brakes, electric motors control the movement of the ram via belt or gear mechanisms that drive ball screws. Typically, a hybrid or electric press brake can be up to 20 to 30 percent more energy efficient than a traditional hydraulic press brake. Electric machines have relatively high bending speeds, but they are not as fast as hydraulic machines in approach or retraction speed. However, they are a great middle ground between the two types, and can reach accuracy’s of up to 4 microns. Mitsubishi and Adira have partnered up to bring you some of the best press brakes available. While the electric and hybrid models provide their perks, Adira heavy duty brakes are best for high-tonnage applications. For more information, please check out Mitsubishi’s BH Series Diamond Hybrid Press Brakes.

For more information, please email us at info@carlsonfab.com. For all of our press brakes, please click here.

Also See:

• MITSUBISHI BB SERIES DIAMOND ELECTRIC PRESS BRAKE

• ADIRA PRESS BRAKES

• ELECTRIC / HYBRID PRESS BRAKES