Page 12 - MetalForming September 2011

Tech Update
New Plasma-Cutting Torch Shapes
and Materials Increase Thickness Range
A group of engineers and product managers at Hypertherm, Hanover, NH, a man- ufacturer of plasma-arc-cutting (PAC) equipment, logged hundreds of hours on the road, talking to numerous customers during visits to scrap yards, ship yards and other high- use cutting environments, determined to rethink cutting-torch design. After a year of field study, the engineers decided to focus on three areas to optimize torch design:
• Improve robustness;
• Optimize handle ergonom- ics, while also improving goug- ing and cutting access for tight locations; and
• Develop a shorter torch for robotic and pipe-cutting applications.
The engineers spent two years prototyping torches and conducting heat, impact and
cut tests. With testing complete, they then set out to find the right type of plastic for the torch body, and a shape ideal for gouging and cutting in tight places. Tradition- ally, torch shape has been limited by the need for an internal plunger to bring the elec- trode in contact with the nozzle and initiate the arc. The plunger, and the wires attached to it, needed room to move within the torch shell, restricting the choice of shapes and angles.
The solution was found by working inside out, first developing an entirely new con- sumable design that replaced the plunger in the torch with a blowback spring in the electrode. This technology, dubbed Spring Start, enabled Hypertherm to design a near- ly straight torch that angles down just 15 deg. at the tip. This allowed engineers to narrow the neck of the standard hand torch for greater visibility, and to change the shape so that it could be held at either a 75- or 90-deg. angle to the workpiece.
Lastly, engineers went to work developing a mechanized torch with the same level of innovation and flexibility. Their solution was to replace the one-piece mechanized barrel with a modular design that allows users to work with the standard 15-in. torch, or to remove a section from the barrel to create a 6-in. mini torch better suited for robotic applications.
Hypertherm, Inc.: 603/643-3441; www.hypertherm.com
Nano-Ceramic Grease Proves Ideal for Conveyors
DayLube high-performance grease from Dayton Progress, Cincinnati, OH, offers a lower coefficient of friction at all temperatures than traditional PTFE greases. Use it on conveyors and their bearings, and on bushings cables, cams, chains, gears, lifters, machine parts, robotics, slides, wear plates and more. The grease uses nanoceramic particles that provide continuous lubrication to steel surfaces and that provide extraor- dinary adhesion to extend life by as much as 10 times that of other greases.
DayLube operates at -40 to 800 F, and the nanoceramic particles remain intact to 2500 F. It survived the ASTME 4-ball weld test with no weld and minimal damage to all ball bearings.
According to Dayton Progress representatives, manufacturers using DayLube on their conveyors report significantly longer service life—up to 10 times longer than traditional PTFE lubricants.
Dayton Progress: 937/859-5111; www.daytonprogress.com
Press-Brake Manipulator System for Heavy Plate
Serapid, Inc., Sterling Heights, MI, pro- vided a dual LinearBeam push-pull posi- tioning system to Pacific Press Tech- nologies, Mt. Carmel, IL, for manipulating heavy plate in press-brake forming oper- ations. The system moves plate weighing as much as 5000 lb. It travels at 15 ft./min. and cycles once every 10 min. It replaced manual positioning, an operation requiring two operators, cutting manual labor in half and increasing productivity by four times.
The Serapid LinearBeam is a mechan- ical actuator used for load transfer and is rated to 400-ton capacity.
Serapid, Inc.: 586/274-0774; www.serapid.com
Laser Cutting at 6kW
Mazak Optonics Corp., Elgin, IL, has taken its SuperTurbo-X Mark III 2D laser- cutting system to a whole new level by increasing its power output to 6000 W, increasing its capacity in mild and stain- less steels. The STX Mark III utilizes Mazak’s hybrid platform and provides con- stant-beam length construction for uni- form cutting across the machine table.
Additionally, the system utilizes sev- eral advanced features found in Mazak’s high-end Hyper Series machines, including intelligent setup functions for automated nozzle spatter removal, a three-station nozzle changer and focal-point measure- ment and adjustment capability. These functions are part of the Mazak Opti-Pod, which helps minimize system setup time and extends unattended operation for longer periods of time while still main- taining optimized machining conditions.
The machine is available in table sizesof4by8,5by10and6by12ft., with power output of 2.5, 4.0 and 6.0 kW. Optional automation equipment includes load/unload cells and flexible manu- facturing systems.
Mazak Optonics: 847/252-4500;
www.mazakoptonics.com
10 MetalForming/September 2011
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