New Punching Technology

November 1, 2009

New technology in punching is coming in many forms these days as new tooling, robots, and software are created specifically for this application.

Unlike the automotive industry, sheet metal parts are not always the same. Robot evolution is already beginning to solve the problems of working with dissimilar parts and significantly reducing nonvalue-added operations.

“Robots will be the future of automation,” said Terry Stewart, LVD Strippit product manager for punching. “The traditional linear systems have too many moving parts, which makes them unreliable without flexibility. Robots are highly reliable and easy to install and use. More tasks will be assigned to robots as they gain popularity in sheet metal part production.”

LVD Strippit has developed a punching cell that incorporates a robot loading/unloading station with the company’s V series of CNC turret punch presses.

Offline Programming

As robots and punching systems get more complex, the software behind them also must evolve.

Because of this, LVD Strippit has released CADMAN®-P 3-D offline programming software for CNC turret punch presses.

The software is a PC-based CAD/CAM system that operates on a Windows® platform. It provides offline programming, allowing users to combine fabricating design and programming functions into a single package.

The latest software has a new interface that features graphical visualization techniques for autonesting capabilities.

The module provides automatic tool selection and turret configuration, including the identification of optimum tool stations and turret loading.  This software module provides support for all standard and advanced punching functions, including autoindexing stations and multitools as well as standard and specialty punches.

New functions include the support of a greater range of wheel, scribing, and tapping tools; optimized management of part evacuations (drop door or robot gripper); and improved micro-joint programming.

For more information, visit www.lvdgroup.com.

Eliminating Scratches

The latest generation of TRUMPF’s TruPunch 5000 has increased speed when compared to previous models, and a new active die option, virtually eliminates scratches during processing, according to the company.

With the active die, each time the sheet is positioned, the die is lowered slightly so that it does not contact the sheet. The moveable die also expands the forming possibilities of the machine since the total distance between the table and punch can be used.

In addition, the active forming stroke from below the sheet allows the use of larger tools and makes it possible to mark the underside of the sheet.

The speed increase, which equates to roughly 10 percent, results in 1,400 strokes per minute for medium format and 1,200 strokes per minute for large format - without using more energy. This punching center can process a maximum sheet thickness of 0.3 in.

This system also can be automated modularly with a variety of components, such as the SheetMaster and a cart system with belt drive or tracks for the automatic loading and unloading of sheets, as well as the GripMaster, which removes and stacks scrap skeletons.

For more information, visit www.us.trumpf.com.

Automating Component Identification

Thanks to a new tooling kit, there is another method for marking fabricated parts five different ways during the punching process.

The EasyMark™ system from Mate is a thick turret application tooling system for machines without a bottom-stroke forming feature. Using the programming software in a CNC punch press, this tool system can be setup to perform five different marking operations automatically:

1. Write numbers, dates, and other identifying information on a part surface using a special marker. No penetration or metal removal is involved when using the tool in this mode. The special marker does not dry out for two weeks or more, and the marked information is later erasable if desired.
2. Etch the sheet metal surface with permanent marking information using one of two (120-degree and 150-degree) diamond inserts. 
3. Cut or scribe protective film on sheet metal surfaces using a brass insert to expose localized areas on the part without damaging underlying metal material.
4. Create cone-shaped indentations (center point down) on the part surface to locate the part with other components for later assembly.
5. Perform dot-matrix marking using a carbide insert.

“Fast and reliable component identification is critically important in today’s manufacturing environment,” said John Galich, Mate’s marketing manager. “Fabricating and assembly processes frequently take place in multiple locations. Before being moved from the turret press to the next operation, components need to be accurately marked so they can be easily identified.”

For more information, visit www.mate.com.