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Processes
in sheet metalworking
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CAD
fig. 1.1
CAM
PRODUCTION
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The nested information is then sent to the machine tool for processing. The
machine tool could be a shear, a laser cutting machine or a CNC punch press
that is able to produce 2D contours and shapes.
A press brake is used to bend the unfolded part into a 3D part. The bending
process should begin when it is established that the part can be produced. This
is the third step in job preparation, which should be completed during the
design of the part. This method of concurrent engineering ensures that parts can
be produced with the available production resources and leads to lower
throughput times.
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3D
Tools
Bending technology
Parts
CAD
Material
Sheets
Tools
Laser technology
2D
fig. 1.2
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fig. 1.3
1.2.2 bending
The 4 steps of job preparation for bending include:
Definition of bending sequence
Calculation of gauges
Set-up of tooling
Post-processing.
A tool set-up and an optimal bending sequence must be established in order to
avoid a collision of the part with the machine or tooling. The positions of the
gauges are automatically calculated and the tools are placed on the machine
(section 5.3). The production of a part can be simulated in virtual reality (figure
1.4). Finally all information is converted into a machine-compatible code,
which is known as post-processing.
fig. 1.4
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fig. 1.5
1.2.4 punching
The job preparation for punching is similar to that of laser cutting:
Sheet nesting
Applying punching technology
Defining the punching sequence
Post-processing.
Unlike laser cutting, the sheet processed on a punch press is held in work
clamps and moves in two axes during the punching cycle. Stability of the nested sheet is critical in order to maintain accurate parts and efficient production.
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See section 3.3 for information on restrictions for punching. The complete processing can again be simulated on the computer (figure 1.6). Finally, everything
is converted into a machine-compatible code.
fig. 1.6
1.2.5 shearing
When cutting rectangular strips with a guillotine shear, there is no need for job
preparation after calculating the unfolded part. Most right angle shears are integrated with a punching machine, so job preparation for this type of application
is combined with the punching process.
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fig. 1.7
Machines with an automatic sheet supply and/or with automatic part evacuation must be able to perform several jobs without operator intervention.
Therefore these machines are equipped with a job-list (figure 1.8) which
defines the sequence in which several jobs can be executed together with the
sheet that each job must use. During the preparation of the job-list, jobs can be
loaded from the central database using a custom-defined selection criterion.
During the execution of the job-list, the machine will automatically provide a
production status to the central database.
fig. 1.8
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The production follow-up can easily be accomplished by consulting the central database. Status information about each part and each nesting can be
requested (figure 1.9), including the production machine that produced the
part, the number of parts to be produced, the number of parts already produced, and the production time and cost once the part is finished.
fig. 1.9
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1.4 logistics
1.4.1 manual sheet warehouse
To maximise floor space, batches of sheets are often stacked in a tower storage
system. The tower, which is equipped with a loading system, is placed near the
sheet metalworking machine (figure 1.10) to facilitate loading operations and
minimise material handling time.
fig. 1.10
fig. 1.11
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fig. 1.12
job preparation
bending
sheets
automatic warehouse
sheets
fig. 1.13
2D
part
3D-part
laser
2D-part
punching
2D-part
NC
2D-part
NC
sheets
NC
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fig. 1.14
fig. 1.15