Page 12 - MetalForming July 2014

Tech Update
Next-Generation Parts Cleaning
Using infrared spectroscopy, OFM tech- nology directs a source of infrared light through the lubricating layer. As the light passes through the oil, wavelengths of light are intensely absorbed by the lubricant, irre- spective of its grade or viscosity. An opti- cal detector collects the remaining light reflected from the surface of the strip, allowing the system to accurately determine lubricant thickness.
Dürr Ecoclean, Wixom, MI, introduces EcoCCore solvent-based part-cleaning machines, promising to increase throughput by 30 percent compared to previous technology. The machines are equipped to provide improved cleaning performance, process
reliability and energy savings, say company officials. They use non-halogenated hydro- carbons and modified alcohols to clean parts produced by machining and metalform- ing—wherever grease-free surfaces are required.
Rollforming a Better Metal Door
EcoCCore machines feature two flood tanks, heat recovery, and full-flow plus bypass filtration capabilities. Users can easily switch from non-halogenated hydrocarbons to mod- ified alcohols and back. In combination with appropriate solvents, the machines can even remove chlorinated oils from part surfaces.
When Premier Products Inc., Monroe, LA, a manufacturer of commercial, hollow steel doors and frames, sought to introduce a newly designed door frame to the market, company president Joey Meggs went in search of a customized rollforming machine. The new door frame—a kerf frame profile with a groove for weather stripping—simplifies the application of weather stripping, saving customers valuable time in the field and improving product aesthetics.
The work chamber holds cleaning tanks as large as 670 by 480 by 400 mm, and offers a 200-kg load weight capacity. Cycle time is less than 8 min.
A major step towards improved cleaning quality lies in the new preliminary steam-degreas- ing process. Here, the oil-containing distillate is directed straight into the distilling sys- tem, minimizing oil deposits in the flood tank and an undesirable oil enrichment of the solvent. The result: enhanced degreasing performance particularly beneficial for parts to be coated or laser-welded.
Further, the machines can simultaneously use ultrasound and filtration.
“This wasn’t an idea new to the indus- try, but it was new to us,” Meggs says. To bring the idea to market, Meggs part- nered with Samco Machinery, Toronto, Ontario, Canada. Samco designed and built a rollforming machine that fabri- cates Premier’s parts and maintains the tolerances required for door-framing head- ers and jambs, in varying widths and heights.
Dürr Ecoclean, Inc.: 248/560-2100; www.durr-ecoclean.com
Measuring Oil-Film Thickness on a Coil or Sheet Surface
The oil film on the surface of a coil or sheet finds use as a coolant and lubricant in the rolling process; acts as an anti-corrosion barrier during storage; and provides a crit- ical lubricating layer during stamping. Material with insufficient oil can lead to difficul- ties in the forming process, resulting in defective stampings, increased tool wear, unnec- essary stoppages and lost production. Conversely, material with excessive oil deposits can lead to downstream production problems, panel welding and adhesion issues and painting and lacquering difficulties, as well as have a negative environmental impact.
“We went up to Toronto and ran sam- ple parts to make sure the unit was work- ing properly, and we tested again upon delivery and installation to make sure it was still doing what it was supposed to do after it was transported here,” Meggs says.
Samco Machinery: 416/285-0619; www.samco-machinery.com
To provide metalformers with a reliable and dependable process to instantly and accu- rately measure lubricant thickness, and to determine its distribution across the complete coil or sheet surface, Amepa GmbH (Amepa America Inc., Middleburg Heights, OH) has introduced an oil-film measurement (OFM) system. It’s based on Lambert Beers Law, which states that the thickness of lubricant is directly proportional to the amount of light it absorbs.
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Metalformers can acquire OFM tech- nology in three setups: an automatic inline, real-time system that constantly and simultaneously scans both sides of a coil; a table-mounted version for precut blanks and sheets; and as a portable hand-held device.
Amepa: 440/826 0121; www.amepa.com