the growing versatility of turret punch presses - thefabricator

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Thegrowingversatilityofturretpunchpresses

presses&title=The+growing+versatility+of+turret+punch+presses&summary=Recent+improvements+in+press+drive+technology%2C+machine+control+design%2C+tooling%2C++and+CAD%2FCAM+programming+software+are+increasing+the+throughput+capability+and+the+overall+versatility+of+CNC+turret+punch+press+equipment.)

ThegrowingversatilityofturretpunchpressesNewdevelopments=amoreusefultool

THEFABRICATORSEPTEMBER2004(/publication/fab/issue/116)SEPTEMBER14,2004BY:RICHDAPP(/AUTHOR/RICHDAPP)

Recentimprovementsinpressdrivetechnology,machinecontroldesign,tooling,andCAD/CAMprogrammingsoftwareareincreasingthethroughputcapabilityandtheoverallversatilityofCNCturretpunchpressequipment.

PressDriveFlexibility

Higherhitratesonamechanicalramsystemareadirectresultofthefasteraxisspeedsandquickeraccelerationanddecelerationsuppliedbyservosystems.Amechanicalramhasafixedstrokelength,whichstartsatthefullyretractedpositionandfinisheswiththeramattheexactbottomposition.Thistypeofsystemissimpletoprogramandoperate,butitdoesnothaveallthecapabilitiesofservocontrolledhydraulicramsystems.

Mostadvancesinpunchpressversatilityareassociatedwithhydraulicramsystems.Hydraulicramsystemswereintroducedtoallowthepunchstroketostartandstopatanypointalongtherampath.Startingtheramatapointclosetothematerialtobepunchedshortensconsiderablytheoveralldistancetheramtravels,providingincreasedhitrates.

Thecontrollabledistanceofthepunchassemblyabovethematerialiscalledthehoverheight(seeFigure1).Asthehoverheightdecreases,thehitrateincreases.

Figure1:Thehoverheight,whichisthedistancebetweentheworkpieceandthetool,maybevariedbythepunchpress

operator.Increasingthehoverheightcanpreventacollisionbetweenthetoolandthematerialiftheworkpiecehaspreviouslyformedfeatures.Thedistancetothenextholealsoaffectsthehoverheight.Ifthedistancetothenextholeisshort,asmallerhoverheightcanhelptoincreaseproductivity.Ifthedistanceisgreat,increasingthehoverheightcan

helppreventacollisionifthematerialiswarped.Ifthehoverheightvalueissettoosmall,thepunchassemblyandthematerialmaycollide,particularlyduringlongdistancemovesoverunevenmaterialorpreviouslypunchedformssuchasknockoutsorlouvers.

Ifthehoverheightvalueissettoolarge,thehitratemaybelowerthanthemachine'spublishedspecifications,whichwilldecreasetheturret'soutput.Theprogrammingsystemoftenisusedtogenerateatimeestimateforthejob,andthistimeisusedtoprovideacostestimateforthejob.Toolargeahoverheightwilldecreasethroughputandreduceprofitmargins.

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Figure2:Improvementsincontrolsystemsallowpunchpressestousewheelstyletoolingtoformsheetmetal.Otherwheelstyle

toolscanslitthematerial.

Figure3:Graphicscreenspromptoperatorsthroughtoolandjobdatainput,simplifyingsetupandincreasingthroughput.

Someturretpunchpresscontrolstakeintoaccounttheprogrammedmaterialthicknessandtheupcomingaxismovedistanceandthenautomaticallycalculatetheoptimalhoverheightforthataxismove.Thepunchingtooliskeptclosetothematerialonshorttablemoves.

Whenthehitsrequiredarefartherapart,thesystemautomaticallyincreasesthetoolhoverheighttoprovideclearanceforsheetwarpage.Thishelpsachievefast,reliablemachineoperationwithoutoperatororprogrammerinvolvement.

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Theabilitytocontrolnotonlythepositionofthetoolbutalsothevelocityofthetoolduringapunchingorformingoperationhasopenedthedoorfornewtoolinginnovations.Newlydevelopedtoolingusestheflexibilityoftheramcontrolcoupledwithautomatictoolrotationtechnologytoallowabroaderrangeofpunchingandformingcapabilities.

Wheelstyletoolingwascreatedasaresultoftheabilitytopositionatoolpreciselyandtorotate,orindex,thetooltoproducemorecomplexshapesinasheetmetalpart.Usingaccurateramcontrolandautoindexing,arotatingwheelshapedtoolispressedintothematerial.Asthetablemovesthematerialthroughthewheelstyletool,thewheelslitsorformsthematerial(seeFigure2).

Oneexampleofwheelstyletoolingisaribbingtool.Fabricatorsoftenuseheavygaugematerialstoincreasetherigidityofafinishedproduct.Byrollingstiffeningribsintothematerial,thefabricatorcanusethinnergaugematerialandproduceafinishedpartwiththesamerigidityasbefore.Reducingthematerialthicknesscanlowerbothmaterialandshippingcosts.

Ascribetoolisanotherexample.Adiamondstyluspunchispositionedintothematerialbytheramandremainsrigidwhilethesheetismovedunderthetooltocreatealphanumericcharacters,companynames,orlogos.Charactersizeisunlimited.Thewidthanddepthofthescribecanbecontrolledsosecondaryoperationssuchassheetfinishingorpaintingwillnothidethescribedmarks.

ControlandSoftwareIntegration

Acriticalfactordeterminingthesuccessoftoday'sversatilepunching,forming,andmarkingtoolsistheabilityofthemachinecontrolandpartprogrammingsystemtointegratethespecialfunctionsneededforthetoolstoworksuccessfully.

Mostofflineprogrammingsystemsaredesignedtohandlethecomplextoolingnowavailable.Themorecriticalfactoriswhetherthemachinecontrolisabletoaccommodatethedynamicsofthenewtoolingcapabilities.

Tousethenewesttoolingdesigns,themachinerampositionmustbecontrollabletoallowminuteadjustmentsintoolpositionandtosetthespeedatwhichthetoolentersandexitsthematerial.Forwheelstylecuttingtools,thedistancerelationshipbetweentheupperandlowerwheel,combinedwiththematerialthicknessandmaterialtype,iscritical.Thedimensionsofwheelstyletoolsmustbecorrectlydescribedtothemachinecontrolfortheramtopositionthetoolingcorrectly.

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importantistheprogrammer'sinput.TheprogrammermustusetheproperGcodestoimplementtheproceduresforthewheeltoenterthematerialatthecorrectpositionforthecuttobegin.IfthemachinecontrolhaslimitedGcodesforwheeloperation,eventhoughtheturrethasaservocontrolledhydraulicram,theabilitytocutcomplexshapesmaybelimited.

Straightlinewheelcuttingrequireslesssophisticatedcontrolthandoesradiuscutting.Inmanyinstances,theprogrammermustcontrolthedepthoftheuppercuttingwheelandinputtheproperfeedrateduringradiuscutting.Thefeedratewillchangedependingonthesizeoftheradiusandthecharacteristicsofthematerial.

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Thefeedrateisespeciallyimportantwiththinmaterial,becauseifthefeedrateistoofast,thematerialmaybuckle.Somemachinecontrolsautomaticallycalculatetheproperchangingfeedratesasthewheeltoolentersaradiusandthenacceleratesoutoftheradius.

Themachineoperatorplaysanimportantroleintheoperationoftheservocontrolledhydraulicramsystemusedintoday'sturretpunchpresses.Thedimensionalmeasurementsofthetool,whetheritisapunching,forming,wheelstyle,tapping,ormarkingtool,mustbeinputaccuratelytothemachinecontrol.

Whennewtoolsareloadedintotheturret,thepunchlength,punchtiprecess,anddieheightmustbecorrectlymeasuredandenteredintothecontrol.Moresophisticatedtoolsmayrequireadditionalinputs.Forexample,aformtoolmayhavebothaformheightandalostmotiondimension.Additionally,someformtoolsmayrequireadwellatthebottomofthepunchstroketosetthematerialflow.

Machinecontrolsthathavegraphicallybasedinputscreenscanhelpsimplifyoperatorinput(seeFigure3).Theydisplayapictureofthetoolandprompttheoperatortoinputinformationbasedonthegraphic.

Theflexibilityofprogrammablehydraulicrams,improvedmachinecontrolsandsoftware,andtoolingadvancementscanhelpmakethepunchpressamoreversatileproductiontool,whichinturnhelpsincreasethroughputdecreasesetuptimereduceparthandling,transport,andsecondaryoperationsandimprovepartquality.

RichDappisproductmanagerturretpunchpresseswithStrippit/LVD,12975ClarenceCenterRoad,Akron,NY14001,7165424511,8008281527,fax7165425957,[email protected](mailto:[email protected]?subject=Thegrowingversatilityofturretpunchpresses),www.lvdgroup.com(http://www.lvdgroup.com).

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the growing versatility of turret punch presses - thefabricator

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