FABTECH 2023 – METALFORM, Finishing, Tube & Pipe
Hall D: METALFORM, Finishing, Tube & Pipe of FABTECH 2023, North America’s largest metal forming, fabricating, welding and finishing event.
Posted: July 23, 2023
METALFORM, Finishing, Tube & Pipe (Hall D)
Fabricating & Metalworking is proud to present the FABTECH 2023 Product Showcase, which is an invaluable guide to navigating the trade show floor at McCormick Place in Chicago this September. This FABTECH section outlines some of the products and demonstrations expected to be on display by more than 1,500 world-class suppliers in three exhibition halls. An estimated 45,000 people will attend FABTECH 2023.
Pavilions at FABTECH are dedicated to 3D/Additive Manufacturing, Forming & Fabricating (Hall A); Welding, Welding Automation, Robotics & Industrial Automation (Hall B); and METALFORM, Finishing, Tube & Pipe (Hall D). This article is dedicated to: Hall D– METALFORM, Finishing, Tube & Pipe
New Incremental Forming Simulation Software
In Booth D41130, Accurate Die Design Software, Inc. (Brookfield, WI), North American Reseller and Technical & Training Center for LogoPress, will demonstrate the capabilities of LogoPress software. LogoPress has been developing die design software for the tool and die industry as well as flattening and blank prediction software for many kinds of parts. Since December 2018, LogoPress became an AutoForm company and has enhanced the simulation features of the software.
One of the newest products that we will demonstrate is LogoPress ProgSim12, which is incremental forming simulation software that runs inside of SOLIDWORKS and LogoPress DieDesign software or LogoPress DieDesign PREMIUM software.
The ProgSim performs accurate simulations of forming processes using incremental simulation technology powered by the industry-proven AutoForm solver. ProgSim is both affordable and easy to use and provides results for thinning, wrinkling, splitting, stress, strain, etc. It also provides multiple ways of displaying accurate springback results.
Automatic blank development done using Cut Optimizer in ProgSim eliminates the trial-and-error part of developing a die using physical tooling. The Cut Optimizer option simulates both the cutting/trimming and the forming of the strip repeatedly. After each iteration, Cut Optimizer adjusts the cutting punches that created the initial blank and then simulates the forming process again. It repeats this process until it reaches the target part maximum deviation that had been initially input by the user. This technology has been well-proven in AutoForm Forming’s Trimline Optimization. Don’t go in and out of the press several times as you develop the blank, measuring and cutting new blanks each time. ProgSim incremental forming simulation software will do it automatically. It uses the same AutoForm solver technology for solving as AutoForm Forming uses. Therefore, the formability results between ProgSim and AutoForm Forming are going to be identical and extremely accurate.
New Guide System is an All-in-one System
Agathon Machine Tools’ (Bethel, CT) new Guide System Plus can be the answer to handling increased demands in productivity and the need to reduce overall production costs. The company will be at Booth D41326. To position the mold halves and/or mold components precisely or even close, it’s highly dependent on the centering systems being used. An innovative reinterpretation of existing guidance and centering systems now allows for guiding and centering of the mold halves to be done with one system.
By design, each bushing and pillar comes with a freely positioned retaining ring that is adjustable to various plate thicknesses. This allows for better adaptability when repairing or converting tools to newer guide systems. One component can be used in multiple designs and makes for stress free ordering and for the ability to keep spares on hand.
The guide system bushing is equipped with precision heavy-duty rollers. These allow for much higher travel speeds than conventional slide guides. With minimal line contact by the rollers, there is a significant increase in the serviceable life of the components by a factor of five-to-12 times as compared to slide guide systems. High precision rollers provide consistent, accurate movement of the mold halves/plates, insuring proper repeatability in alignment and achieve consistent part quality surpassing that of conventional guides and centering systems.
The Agathon Guide System Plus comes in 15-, 25-, 32- and 40-mm sizes and we offer engineering design assistance to help you determine the right system for your application.
New Mechanical 110-Metric Ton, 300 SPM Stamping Press
AIDA-America (Dayton, OH), a metal stamping press manufacturer, is introducing the NSX mechanical stamping press at FABTECH. This newly designed two point, 110-metric ton, unitized frame press is capable of speeds ranging from 120-to-300 strokes per minute (SPM). The automotive, appliance, hardware, consumer goods industries, and all industries that depend upon consistent high-volume production, will benefit from the applications of this press system. Accuracy is ensured by a zero clearance, lubrication free, eight-point roller slide guide system and by dual counter rotating eccentric shafts. Press and die integrity are protected by AIDA’s metal seal type Hydraulic Overload Protection (HOLP), the fastest acting HOLP in the industry at 10 milliseconds to zero pressure.
Additional AIDA NSX press features include:
- Low deflection, rigid unitized steel frame construction
- Cast iron slide with detachable slide face
- Induction hardened main gears
- Inboard mounted carbon fiber counterbalances
- Quill mounted flywheel
- Pneumatic combination clutch-brake unit placed outside of the flywheel
- Oversized ball type connection points to minimize drivetrain clearances
- Recirculating oil lubrication system with cycle monitoring
- Variable frequency main motor
- 65 mm stroke length
- Bed size of 50” L-R
- Slide and bolster JIC T-slots on 6” centers
- Floor mounted design for quick and pit-free installation
- Eight programmable limit switch (PLS) circuits
- Quick access, extended range, powered slide adjustment allows easy die access, with auto slide adjust option to maximize slide adjustment range capability
- Plug-and-play control junction box with standard Rockwell Allen-Bradley control, or optional Link OmniLink 5000 or Wintriss SmartPAC controls
There are also options for the NSX, including a peak/reverse tonnage monitor, and eight channel or 16 channel die protection.
Locally engineered at AIDA-America in Dayton, Ohio, the NSX is designed to meet the demands of high-volume stamping operations. See this press in action, running at its top speed of 300 SPM at Booth D40902.
Abrasive Tools for Precision Finishing and Deburring
A Brush Research Manufacturing (East Los Angeles, CA) invention, the FLEX-HONE® Tool provides a superior surface finish with a non-directional or crosshatched pattern. Ideal for cross hole deburring, the tool can finish and deburr simultaneously in a single setup and can be run on any rotating spindle. Designed for a variety of automotive, hydraulic, pneumatic and industrial applications in sizes from 4 mm-to-36”. Fine grit hones in 400, 600, and 800 grit are available for finer finishing tolerances resulting in single digit Ra level finishes. Now available in Diamond and CBN abrasive to efficiently finish and produce the proper edge radius on harder materials such as carbide, ceramic and high nickel alloy steels. Brush Research Manufacturing will be at Booth D40041.
For OD applications, Brush Research’s new Nampower End Brushes are available from 1/2”-to-2” in a high density, solid end brush configuration. These tools offer more cutting points for increased efficiency and performance. The aluminum, hard coat anodized cups hold advanced ceramic abrasive filaments that have lasted three-to-five times longer than the competition during testing. Available in four grits to accomplish even the most challenging of deburring and surface finishing applications. The tool is designed to be loaded directly into your automated machining center to get to work immediately with no special adaptors needed. These ceramic end brushes are the newest addition to our Nampower Premium Abrasive Nylon offering including disc and wheel brushes in ceramic and diamond filament.
Coil Feed Line with Integrated Shear
At Booth D41302, COE Press Equipment (Sterling Heights, MI) will be running a 30” coil processing line equipped with a shear for cutting blanks. The line being demonstrated features COE’s Series 530 Servo Roll Feed, a 3.50”-x-30” Power Straightener, a 15,000# x 30” capacity coil reel and a straight servo shear. The line is capable of handling a variety of materials including copper, HSS and MCRS. At FABTECH, it will be shown processing MCRS.
The system features COE’s SyncMaster Touch integrated controller, which allows operators to manage many of the servo feed, straightener, and coil reel setups and functions from a single touchscreen including line speed averaging loop control, loop depth setting by recipe and automatic lubrication control. SyncMaster delivers high functionality typically only associated with full custom systems.
Feed Line with New Interactive Graphical Display Control
Dallas Industries (Troy, MI), a leading manufacturer of press feeding equipment and controls for the stamping industry, will feature a conventional feed line and its new interactive and advanced graphical display control for press feed lines at Booth D40902.
In a shared booth with AIDA-America, Dallas Industries will have a live demonstration of a conventional feed line running material on the AIDA servo press. The feed line will have Dallas’ unique software features within an Allen-Bradley controls structure. A large graphical display with simple-to-operate features will also be demonstrated.
The 15” new graphical display is designed to maximize productivity during start up and into production by providing an HMI touch and diagnostic screen for the entire feed line process. The new design features an intuitive and easy to follow graphical format that duplicates the machine in operation.
The graphical display can reduce launch and setup time, minimize changeover time, and assist production by providing real time diagnostics for the entire machine.
Dallas Industries’ full line of products includes press feed lines in both conventional and SpaceSaver styles, a wide range of sizes and capacities of servo feeds, heavy-duty straighteners and coil handling equipment.
Future-oriented and Sustainable Solutions for High Cleanliness
Due to rising demands on component quality, new manufacturing technologies, modified processes and/or materials, digital transformation as well as stricter energy efficiency and climate protection targets, parts manufacturers are confronted with new challenges. Moreover, changes in regulations, for example in medical engineering, need optimized processes and plants. All these have an effect on parts cleaning. Even more stringent specifications on particulate and surface tension residual contaminations have to be fulfilled in a stable manner.
Ecoclean (Southfield, MI) and UCM — the division of the SBS Ecoclean Group specializing in high precision and ultra-fine cleaning — are responding to these demands with optimally adapted solutions and innovative developments. Ecoclean will be at Booth D40562. Adapted to the specific requirements and applications (e.g., manufacturing technology and level, type of contamination, cleanliness demands, throughput, weight), different systems are available for batch cleaning with water-based media and environmentally compatible solvents.
For solvent-based cleaning with hydrocarbons and modified alcohols (semi-polar solvents), the product portfolio is comprised of fully enclosed machines carrying the fluid in a closed circuit. All solvent-based cleaning systems come equipped with an integrated distillation system and filtration systems for continuous automatic reconditioning of the solvent. As a result, operator exposure to the solvent is virtually eliminated and an unchanging cleaning quality and long solvent life is ensured. The systems can be used from pre-cleaning through intermediate to final cleaning tasks and preservation, and achieves results in short cycles. Process technologies integrated as standard, such as vapor degreasing, and ultrasonic and injection flood washing, also contribute to this.
Water-based cleaning with alkaline, neutral and acidic media is the technology most frequently employed in industry. True to the principle of “like dissolves like,” it enters the field whenever water-based (polar) contamination — e.g., coolant and lubricant emulsions, polishing pastes, particles, abrasive materials, salts or fingerprints — need to be removed. For water-based part cleaning processes, Ecoclean’s product program includes an extensive range of both standard cleaning systems and customer-specific designs.
Innovative Hydraulic Press Solutions Include Automation, Custom Applications
Greenerd Press & Machine Co. (Nashua, NH) will highlight the company’s extensive hydraulic press and automation capabilities at Booth D40833. Application experts and design engineers from Greenerd will be available to discuss specific user applications and press requirements.
Greenerd offers unique hydraulic press applications and automation solutions for a range of industries. One example that demonstrates these capabilities is an automated two-press, two-robot production cell that Greenerd designed, engineered, built and turnkey-installed that enables unattended production of large aluminum pressure vessels.
Using sensors to locate pallets of blanks that have been placed in a pallet staging area, the first FANUC robot picks a blank, detects and rejects any double-blanks, and transfers the blank to a fully integrated and automated blank lube station. That robot then picks a previously lubricated blank and loads it into a Greenerd deep-draw press with a 76” stroke.
A second FANUC robot then catches and transfers the formed parts to a second Greenerd press for a punching operation. The two-press production cell uses a centralized control station which sets the operating parameters of both presses and controls the action sequences of both FANUC robots. All equipment in the cell is automatically updated with new process parameters when changing between products.
Greenerd’s extensive line of hydraulic presses are available in a variety of styles ranging from gap frame and straight-side to die-spotting and forging presses, with unlimited size and tonnage capabilities. The company has a long tradition of designing, engineering and manufacturing customized hydraulic presses with product handling solutions.
Greenerd is a Tier 1 Industrial Authorized Robot System Integrator of FANUC America Corp., the industry’s leader in automated manufacturing equipment.
Mechanical and Servo Driven In-die Tapping Solutions
Hutchison Tool (Bensenville, IL) will be exhibiting both mechanical and servo driven In-die tapping solutions at Booth D40827. The exhibit will include solutions for a variety of part configurations including follow along units for high strip lift applications, horizontal units for tapping after forming and bottom up tapping units for hand transfer operations. All of these solutions can be supplied in multi-spindle patterns per customer specifications.
Hutchison Tool will also be demonstrating a complete In-die clinch nut system. The clinch nut system will be under power showing the complete process from nut loading all the way to nut feeding to the clinch head. The In-die clinch nut system can feed a wide variety of clinch nut sizes and shapes.
Tools for Quick Setups Save You Time and Money
Lenzkes Clamping Tools (Christiansburg, VA) is known for its high-quality workholding solutions for all types of machines. Visit them at Booth D41035. Products are applicable for machine tables/platen with t-slot and/or tapped holes and feature high clamping forces ensuring quicker and safer changes. Chain clamps provide the fastest and safest way to hold round and bulky workpieces securely in place by low torque settings. The chain clamp product is quite easy to adjust, which increases productivity by reducing setup time. The MQ150 and MQ160 quick release tools offer exceptional stepless, vertical and horizontal adjustment. The unique arch shaped clamping arm provides multiple options regarding clamping position. The MQ160 provides a greater stepless horizontal adjustment due to an elongated slot in the clamping rail.
View Process Monitoring Solution with Automated Ram Height Adjustment
In Booth D41041, Marposs Corp. (Auburn Hills, MI) will demonstrate its process monitoring solution featuring a special automated ram height adjustment capability. The system automatically compensates for variation in sheet thickness, material hardness, tool and machine temperature, speed, etc. during the manufacturing process. Using a mini press wired to the Marposs Brankamp monitoring system and a piece of paper that serves as the variation, visitors will see how the system automatically sends a signal to adjust the shut height of the press to adjust the change.
Marposs’ Brankamp monitoring systems for sheet metal processing (stamping, drawing, coining, piercing, blanking and bending), detect process disturbances such as rising slugs, feed failures, and punch or die breakage, providing 100% monitoring of each individual stroke and protecting the machine and tool from overloads. This helps to immediately identify manufacturing faults as well as part or tool variations, enabling manufacturers to optimize machine efficiency, improve part quality, and limit unplanned downtime and tooling costs.
Monitoring systems are an effective method to gain insight into the forming process and its stability, to detect production faults and quality deviations, and the shut height, if necessary.
For more information on the Brankamp line of monitoring systems for forming applications, visit www.brankamp.com/eng/. Brankamp, founded in 1977 and acquired by Marposs in 2012, is a Marposs Monitoring Solutions GmbH brand marketed through the Marposs worldwide network.
Handheld XRF and LIBS Analyzers Trusted by Metal Fabricators Worldwide
See, touch and hold the Thermo Fisher Scientific’s™ (Waltham, MA) Niton™ handheld XRF and Laser Induced Breakdown Spectroscopy (LIBS) analyzers that are trusted by manufacturers and metal fabricators worldwide for QA/QC applications from alloy verification to metal coating thickness. Thermo Scientific will be in Booth D42625.
Speak with the experienced staff to learn about our proven handheld elemental analyzers including the Thermo Scientific Niton XL5 Plus Handheld XRF (HHXRF) Analyzer, the Niton XL2 Plus HHXRF Analyzer, and the Niton Apollo LIBS analyzer.
Niton XL5 Plus Handheld XRF Analyzer: This offers fast, reliable material verification with unprecedented performance even for lightweight elements. Features include:
- Determine alloy composition and grade for a wide range of metal chemistries faster than ever before
- Improve QA/QC and increase confidence in risk-management practices
- Measure thickness or coat weight of up to four layers of coatings on a specified substrate
- Support layers consisting of pure metals, alloys, and compounds and define substrates consisting of pure metals, alloys, plastics and wood
Niton XL2 Plus HHXRF Analyzer: When durability, performance and productivity are top of mind. Features include:
- Verification of pure metals and alloys in manufacturing
- Quality Assurance testing for positive material identification
- Coating thickness measurements from single element layers
Powder-coated Aluminum Railing Performs at Commercial Grade Level
ULTRALOX INTERLOCKING® TECHNOLOGY (Eagan, MN) manufactures premium powder-coated aluminum railing and framing systems for commercial applications with low-maintenance living in mind. Our dedication to research and development ensures a uniquely engineered railing system which meets commercial/residential building codes throughout North America. Our systems are also designed to directly reduce lead times, while still performing at a commercial grade level. With our hidden fastener design, you can expect a refined and elegant look that will last. We ensure this with our 20-year warranty, and 10-year warranty for coastal projects. Find out how we accomplish all of this by visiting us at Booth D41347 where we will have on display some of our most popular products as well as a demonstration of how we manufacture our hidden fastener railing.
New, Powerful Features Added to Press Automation Controller
Wintriss Controls Group (Acton, MA) will be demonstrating new, advanced features in its SmartPAC PRO Press Automation Controller, and in its ShopFloorConnect® OEE and Data Collection Software at Booth D41118.
Wintriss has developed the world’s most advanced Programmable Limit Switch (PLS) — new ProCamPAC PRO, for its flagship SmartPAC PRO Press Automation Controller. The new PLS includes counter driven outputs that operate only on specified strokes to precisely control gagging operations, new asymmetrical toggle outputs for controlling complex configurable tooling, and additional timed outputs for even greater versatility.
A new Toggle Cam Output performs an asymmetrical toggle function, turning an output off or on for different stroke amounts. The output can be used to operate diverter gates and to control complex gagging operations. The new On/Off Counter Cam Output precisely controls functions that need to operate at a preset interval instead of on every machine cycle. Operating similarly, a new Pulsed Counter Cam Output is programmed with an “on angle” and a dwell time instead of an on/off output.
Useful when running configurable tooling, a new Channel Always On Cam Output will simply turn on and stay on until a new tool is loaded. The ProCamPAC PRO PLS also features a unique Triggered Cam Output which actuates a precision one-time cam timing signal based on a preset trigger such as an external input from ancillary equipment, an extended period of machine idle time or a job change. This output type is ideal for diverting parts during a warm-up period, QC checks, or when bad parts are determined by an outside measuring system.
Attendees can also see the new Advanced DiProPAC available on the SmartPAC PRO Press Automation Controller, which boasts more than 10 new capabilities for even greater die protection for presses. Highlights include a new customizable green sensor type called Green Flex™ that combines all the elements of the other green sensor types. This versatile cyclic sensor can monitor intermittent events such as gagging operations, and also has a function that allows for the precise monitoring of events that need to occur multiple times per press cycle.
In addition, Wintriss has expanded the static sensor monitoring capabilities in DiProPAC with auto-reset, programmable bypass angles, and minimum actuation time settings.
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