MARCH 2002 .wawhitne Power, Speed, Size, Surprises … · of Esterline Technologies. For more...

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Power, Speed, Size, Surprises

Add to Lasertron’s

Cutting Capabilities

Whitney Open House

April 16 & 17, 2002

Roadtec’s Rebuilt 3600 ATC

The Investment Advisor

Advantages and Flexibility

of Precision Plasma Cutting

Determining Punch

ProblemsINS

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MARCH 2002

CONTENTS

Letter from the President ............................................3

Whitney Open House ....................................................3

Whitney News Briefs ....................................................5

Power, Speed, Size, Surprises Add To Lasertron’s Cutting Capabilities ........................................................6

Laser Power: When is Higher Better? ................................8

Systems Control Backs into Snow Plows and New Product Success ....................................................10

An Advantage to Rough Times! ......................................12

Roadtec Paves the Way with Rebuilt 3600 ATC................14

Introducing the ADVANTAGE…Plus! ..............................16

Advantages and Flexibility of Precision Plasma CuttingTuttle, Inc. & Rivers Metal Products ................................17

A Move For Better Tooling Production............................19

Determining Punch Problems:What the slug can tell you ..............................................20

New Tooling Inserts Save Money ....................................22

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2216 17

The Whitney Metal Fabrication Newsis published by

W.A. Whitney Co.,P.O. Box 1206,

Rockford, IL 61105 Phone: 815-964-6771

Fax: 815-964-3175www.wawhitney.com

W.A. Whitney is a subsidiaryof Esterline Technologies.

For more information on any articleor product, call us at 815/964-6771

or e-mail [email protected].

Editor

Sue Roberts

Production Manager/Art Director

Jeff Hoffman

Circulation Manager

Becky Edmundson

Contributing Writers

Al JulianMarketing Manager

Punch/Plasma

Paul MuraskiCustomer Service Manager

Rick KosmalaMarketing Manager

Laser

Ted BrolundRetired Past President

W.A. Whitney

© 2001, W.A. Whitney, a subsidiaryof Esterline Technologies.

March 2002

With today’s push on reducing costs, creating efficiencies, andeliminating waste, part production flexibility is more importantthan ever.

During the Open House, join us to see how parts from anyWhitney process – punch/plasma, plasma only, or laser – flow toa Pullmax 110 Ton Opti-Flex Press Brake, and on to an ABB Flex-Arc® robotic welder. Absolutely no clean-up is needed regardlessof which Whitney machine produces the parts.

The demonstration assembly shown during the Open House isa winch mounting plate similar to those used on military vehicles.

www.wawhitney.com Whitney Metal Fabrication News • March 2002 — 3

Preparing for Industry’s Return to Profitability

You might have read about thefruitless discussion on the issue ofwhether we experienced a recessionlast year or not.

Bottom line for the manufacturing industry was metal forming has seen capacity utilization as low as 70 per-cent; far below the 80 percent mark ofa healthy industry.

You probably have seen your mar-gins and order volumes erode. Franticinventory reduction efforts took place in the fourth quarter. Difficult capacityadjustments have been made.

We predict the outcome of this re-cession will be quite different thanthose of the past; that the recoverywill be faster than ever before. Thereason is simple, yet complex.

Most of us in manufacturing spentthe last decade implementing manu-facturing models void of inventory.With the supply chain empty, the

slightest uptick in orders will create instant backlogs.

Are you prepared to respond? If you can, will you be profitable in theprocess?

Trying to answer these issues, wehave chosen Return To Profitability asthe theme for our Spring 2002 OpenHouse.

Presentations will focus on elimi-nating non-value added operations, in-ventory reduction and establishingmanufacturing cell technology thatcombines cutting, NC-bending and robotic welding.

See how we at Whitney have implemented lean manufacturing tech-niques such as value stream mapping,Kanban and our rapid improvementprocess. All will be demonstrated andyou can discuss your ideas and prob-lems with our training and engineeringstaff members.

You will see demonstrations of thelatest technology in punching, plasma,and laser cutting. As a leading manu-facturer offering multiple cuttingprocesses, we will evaluate your partsand give you unbiased advice on theadvantages of each process.

NC bending and robotic weldingcomplete the manufacturing processas integral parts of our demonstra-tions. And there is always more to see.

Please accept my personal invita-tion to attend.

I look forward to seeing you inApril.

LETTER FROM THE PRESIDENT

by Joe Mayer, President, W.A. Whitney Co.

Streamlining Downstream Processes

Join us for Whitney‘s Open House

April 16 & 17, 2002

Whitney machines involved in producingparts for the winch mounting plate are thenew 3400 XP Punch/Plasma Combination;the ADVANTAGE Precision Plasma CuttingMachine; and the PlateLASER™.

The main part of the winch mountingplate goes to the Pullmax Optiflex withbending power ranging from 88 tons to 250tons. Low set-up times and excellent pro-cessing accuracy make the Optiflex a goodfit with a single piece flow environment.

The slot and tab design of the winchmounting plate parts allows the variouspieces of the assembly to move to ro-botic welding in the ABB Flex-Arc‚ with-out complicated fixturing. The weldingprocess itself is simplified, the weldingtime reduced.

The same winch mounting plate thatyou will see in production is the “star” ofthe morning seminar New ManufacturingTechnologies for Increasing Profitability.

Seminar speakers will follow the partfrom its 3D CAD design, to part produc-tion nested for maximum material usage,and through the secondary processes ofbending and automated welding. Theseminar will also present strategies forimplementing short-run forming.

Be sure to bring your questions andapplication challenges to the WhitneyOpen House. Together we are ready forour “Return to Profitability.” ◆

4 — Whitney Metal Fabrication News • March 2002 W.A. Whitney — The Leader in Plate Technology

During the Open House, join us to see how parts from any Whitney process – punch/plasma,plasma only, or laser – flow to a Pullmax 110 TonOpti-Flex Press Brake, and on to an ABB Flex-Arc robotic welder. Absolutely no clean-up isneeded regardless of which Whitney machineproduces the parts.

3400 XP Punch/Plasma Combination3400 XP Punch/Plasma Combination

PlateLASER™PlateLASER™

ADVANTAGE Precision PlasmaCutting Machine

Pullmax 110 Ton

Opti-FlexPress Brake

Pullmax 110 Ton

Opti-FlexPress Brake

ABB Flex-Arc Robotic WelderABB Flex-Arc Robotic Welder

ADVANTAGE Precision PlasmaCutting Machine

Two new employees have joined the Whitney team:

David L. WhiteTooling Sales & Marketing ManagerDavid L. White recently joined Whitney as Tooling Sales & Marketing Manager. White works with the development of ad-

vanced tooling, assists the distributornetwork with tooling applications, andworks directly with fabricators for spe-cial needs and trouble-shooting. He isan integral part of the training processfor new and existing customers.

"My personal goal is to make thepurchase and use of Whitney toolingeasy," says White. "We are working toextend the life of our punches and dies,to simplify the process of fulfillingshaped tooling needs, and to continuemaking the ordering process easy

whether it’s through Online Ordering via Whitney’s home page,phone or fax."

White’s experience includes training as a tool and die maker,CNC programming and application work, and sales of precisionpunches and dies, components and machine tools.

Contact White at 815/490-0321; fax 815/964-0831; or viaemail at [email protected].

Jon KrumSouthwestern Regional Sales EngineerJon Krum has joined Whitney’s sales staff as Regional Sales

Engineer for the SouthwesternUnited States. Krum is responsible for providing technical sales supportfor distributors and customers, andmaintaining the distributor networkwithin his territory.

Krum’s background includes extensive experience with high techCNC machine tools. He is experiencedin customer sales and service, researchand development, and application engineering.

Contact Krum at 815/490-0487;fax 815/964-3175; or email at [email protected].

Modern Machinery Hosts Fabricating Machine Tool ExpoA new facility, a grand opening celebration, and new technol-ogy demonstrations highlight the Midwest Fabricating MachineTool Expo hosted by Modern Machinery Company, 1260 EdisonDrive, Cincinnati, OH, on April 23, 24 and 25.

Thirty different manufacturers will fill the new showroomwith equipment, tooling and displays.

The three-day event features hands-on, up-close equipmentevaluations, answers to technical questions, and special "at-show" discounts. Dynamic new product demonstrations in-clude Whitney’s new,“Xtra Performance” 3400 XP punch/plasmafabricating machine that produces heavy-duty parts faster thanany other machine available today.

For additional information or to register call 800/589-1444 or513/381-3550 or visit www.modernmachinerycompany.com.

Larger Facility, More Services for Diamond MachineryDiamond Machinery, formerly in Keller, TX, moved to a new facility. Their new location is in Endeavor Park in Roanoke, TX.

Dennis Diamond, president, says that the new building andlocation helps them better serve their customers and providesroom for future growth. In addition to more office space and alarger, more accessible warehouse and demonstration area, thenew facility will house a service department with engineerstrained to repair and maintain all products sold by Diamond.

New contact information:Diamond Machinery Company14789 Endeavor WayRoanoke, TX 76262Phone – 817/430-1919Fax – 817/430-2929www.diamond-machinery.com


WHITNEY NEWS BRIEFS

Jon Krum

David White

Two New Employees AssistWhitney Customers

The Midwest Fabricating Machine Tool Expo will be hosted byModern Machinery Company in Cincinnati Ohio.


Stainless turnstiles for the world’s largest amusement park;stainless art to adorn fitness center walls; plastic medicine cap-sules with experimental holes; copper and stainless connectorsthat fit comfortably on the end of a finger; carbon steel 1-1/4"thick parts that demand an 80" x 160" table; prototypes of allsizes and materials…that’s what you find cut, pierced, bent,etched and finished at Lasertron in Sunrise, Florida.

Press brakes, welders, finishing equipment and particularlythe nine different lasers — each with a very distinct capability— give Lasertron the “cutting edge.”

Laser capabilities have steadily grown and the shop ex-

panded to the current 18,000 square foot facility. Twenty-fiveemployees keep production going around the clock.

“When most of the world envisions having something lasercut,” explains Gary Geller, Lasertron’s founder and president,“they envision a single laser. That’s not it. Each laser has a dis-tinct capability.”

Geller began Lasertron as a one-man, no-frills shop in 1979.His growth philosophy was very specific. Buy only first modelsof new lasers with advanced capabilities, work with the manu-facturers to hone production processes, and be the first to offerthe results to the market.

He keeps his edge by getting a head-start,“You learn how touse the new laser. You know what it can do. When anybody elsebuys one they have to go through the same learning curve butyou’re already ahead and have the customers.”

Unusual applicationsLasertron specializes in “experiments” and prototypes, often pro-ducing only one piece or a small lot size. Other capabilities suchas laser engraving, forming, welding, and specialty finishing havebeen added to satisfy customer demand. But cutting, the bulkof the business, is where Lasertron excels and sees the greatestprofits.

“A lot of our projects don’t even look suitable for a laser,”Geller explains,“But somebody wants to know if the laser cutwill work. So there are a lot of things we do that seem to makeno sense at all. Some of them end up cutting great on a laser.Then all of a sudden, you’re in a different business.”

“Big” attractionsAbout a year ago, Geller moved two machines out and struc-turally altered his plant to accommodate his latest acquisition,the PlateLASER™ from Whitney.

The initial attraction of the PlateLASER was three-fold. Power,speed and size.

And, following with Geller’s business philosophy, he pur-chased the first PlateLASER and worked closely with Whitney tofine-tune the machine’s abilities.

Power, Speed, Size,Surprises Add ToLasertron’s CuttingCapabilities

PLATELASER APPLICATION

The PlateLASER added the capability of cutting 1-1/4" steeland specialty metals. However, it’s linear drives make it thelaser of choice for cutting thinner materials.

Lasertron President Gary Geller maximizes PlateLASERproductivity, using it to cut thick and thin materials.Lasertron President Gary Geller maximizes PlateLASERproductivity, using it to cut thick and thin materials.


Geller had purchased a 6 kW laser prior to the Whitney, butexperienced challenges ranging from internal machine softwareto repeatability. That changed when he began using the 6 kWlaser combined with the Whitney PlateLASER platform.

The 6 kWs of power allowed Lasertron to quickly and accu-rately cut thick stainless and carbon plate (up to 1-1/4"), with theemphasis on cutting the thicker specialty metals. This new abil-ity has Geller capturing business from conventional machining,plasma and even waterjet processes.

According to Geller, his 3 kW laser struggles to cut 1/2" stain-less at 5 or 6 inches a minute. The Whitney multiplies that speed— in some cases up to six times — depending on the complex-ity of the part. In thin metal the increases can be even higher.That means more productivity in less time as well as savingsin cutting gases and electricity.

The size of the work tables — 80" x 160" handling plateup to 4,600 pounds — increased the size of parts Lasertroncould offer. The dual shuttle tables, which allow loading material or unloading a nest of parts while the machine is cutting, is another time saver.

Predictable resultsOperators became comfortable with the machine very quickly,comparing it to operating a desktop computer. Whitney’s Intelli-gent Laser Control (ILC) with the Material Parameter Library(MPL) simplify operation for predictable results.

Identify the material to be cut and the part configuration andthe MPL automatically tells you the cutting and piercing speeds,the gases required, the gas pressure needed and the lenses tobe used.

“Our operators love the PlateLASER,” says Geller. “The resultsare predictable … you get the same thing time after time. Thatcuts down on the level of frustration from where you walk inone day and can do the job and you walk in the next day andyou can’t. That’s important.”

For some applications Geller uses the PlateLASER in an unex-

pected manner. He uses the high power to make very thin, intri-cate cuts in a 1/2" steel.

Surprising advantageAn unexpected advantage came from the linear motor drivesthat are not typically available on a machine for cutting plate.

With fast processing of thin material, the motion systemneeds to accurately keep up with cutting speeds. In most higherpower plate cutting lasers, the motion systems become the lim-iting factors so the speed available because of the higher powercannot be maximized when cutting thinner material.

That’s where the PlateLASER’s linear motors come into playmaking it a truly “thick to thin” machine.

“Normally somebody interested in cutting heavy plate wouldnot go to the expense of linear drives. Whitney put them on thislaser. There is no inherent advantage when cutting thick parts,but for cutting thinner parts, where you can go very fast, there isa substantial advantage,” says Geller.

The Whitney was added to Lasertron’s shop floor to cut very thick,large parts. And it does that well. But it is also consistently used to

cut thin gauge parts that were formerlyprocessed on lower power lasers.

“Just about everything that we havewe try to put on the Whitney. We defi-nitely do everything that is thicker than1/4" for carbon steel and everythingthat is thicker than 3/16" on stainless,”Geller adds.“We even reprogram partsthat were done on our 3 kW lasers andput them on the Whitney. We’ll makethe same quality part but we’ll get morebang for the buck because there’s morepower to work with.

“It’s the most advanced machine —the topic of party conversation. Whenyou say I work on a machine that cuts 1-1/4" stainless, it’s something peoplejust talk about.” ◆

Laser cutting experiments, prototypes, parts from plate up to80" x 160", and delicate connectors are produced at Lasertron.

Thick stainless and mild steel are cut on the PlateLASER with “predictable” results.

What makes the PlateLASER so innovative? Its ability to manageand take advantage of the 6 kW laser by:

1. Managing the heat generated by a 6 kW laser in thebeam delivery system to provide consistent results dayafter day.

2. Rapid pierce to process thick plate steel fast with minimalheat input to the material. Pierce time for 1" steel is 2.5seconds.

3. Ability to use up to a 12.5" focal length lens in order toprovide minimal draftangle in thick plate im-proving part accuracies.

4. Linear Motors for increased accuracy,repeatability, reliabilityand faster processingspeeds.

5. Independently pro-grammable standoffand focal height for reduced setup.

6. Constant beam pathlength to insure accurate parts across the 80" x 160" cutting envelope.

7. 4,600 pound capacity shuttle table to process plate steel.

Whitney’s PlateLASER is designed to process from “thick tothin” steel fast, accurately and repeatably. The PlateLASER hasthe power to cut thick plate steel that lower powered lasers can-not process, and is still more than capable of processing thingauge steel very competitively.

So when is a 6 kW laser the right choice? It depends on theapplication.

Reactive CuttingReactive cutting occurs when using oxygen as the assist gas. Re-active cutting is typically used when processing mild steel. Reac-

tion of oxygen with the heated material creates an exothermicreaction increasing the heat input to the steel thus allowing thesteel to be cut. In this process, the oxygen assist gas actually per-forms most of the cutting while the laser is used as the heatsource to generate the exothermic reaction. Too much heat,however, leads to a condition known as self-burning, destroyingrather than cutting the material. Therefore, in many instances, a6 kW laser only provides marginal benefits.

The benefit of a 6 kW laser starts when processing 3/4" andthicker mild steel.

A 6 kW laser can process3/4" mild steel faster andmore consistently than a 4 kWlaser because of the addi-tional power. Approximately4.5 kW is the optimum powerlevel to process 3/4" mildsteel. It is possible to process1" mild steel with a 4 kW laserbut the operating window isvery small requiring perfectsetup and machine perform-

ance. Consequently, the yield per sheet suffers at 4 kW and ismuch greater with a 6 kW laser. Finally, a 6 kW laser is the onlychoice when processing 1-1/4" mild steel.

Figure 1 shows the power required to process differentgauges of A36 mild steel.

Non-Reactive CuttingNon-reactive cutting occurs when using an inert gas as the as-sist gas. The most common gas used is nitrogen. Non-reactivecutting is typically used when processing mild steel, specialtymetals (stainless steel, inconel, hastelloy, titanium, etc.) and alu-minum. In this process the laser itself actually performs most ofthe cutting while the inert assist gas is used to cool the materialand remove the molten material. Cutting speeds are directly re-lated to laser power.


Laser Power: When is Higher Better?

A technical article in a leading trade publication recently stated the importance of NOT integrating a

high power laser to a machine designed for a lower power beam. Whitney has embraced this phiosophy

for a long time and after years of research & development introduced the PlateLASER™. A machine

designed from the bottom up specifically for higher wattage lasers.

PLATELASER APPLICATION

a 6 kW is the right choice for OEM’s that have

the proper application requirements and job

shops that want to increase their profitability

by having a competitive advantage. A higher

power laser, like Whitney’s PlateLASER,

offers faster overall processing times and

additional processing capabilities.

Therefore, when using non-reactive cutting, 6 kW lasersprovide significant benefits in terms of faster cutting speedsand the ability to process thicker material.

Many companies use non-reactive cutting to process mildsteel. The main advantages to using this process with nitrogenare faster cutting speeds on thinner gauge materials and theelimination of oxidation along the edge of the part.

Traditionally companies have added secondary operations toremove the oxidation so that powder coatings adhere withoutflaking off the edges of the laser cut part. Today, with non-reac-tive cutting, the secondary operation can be eliminated.

Figure 2 shows the power required to process different thick-nesses of A36 mild steel using nitrogen as the assist gas.

When processing specialty metals non-reactive cutting ispreferred because it produces dross free parts with ma-chined-edge quality. Cutting specialty metals is where a 6 kWlaser is at its best. The additional power cuts thicker specialtymaterials — as well as thinner gauge — at much higher

speeds while maintaining the machined-edge advantage.Figure 3 shows the power required to process different thick-

nesses of 304 stainless steel. The process information for otherspecialty metals is similar.

Finally, when processing aluminum, non-reactive cutting isthe preferred choice because it produces finished parts withmachined-edge quality, again without heat affected zones.Processing aluminum is entirely a function of power andtherefore a 6 kW laser cuts thicker — as well as thinner — material faster.

Figure 4 shows the power required to process different thick-nesses of aluminum.

In conclusion, a 6 kW laser is not for everyone. It is, however,the right choice for OEM’s that have the proper application requirements and job shops that want to increase their prof-itability by having a competitive advantage. A higher powerlaser, like Whitney’s PlateLASER, offers faster overall processingtimes and additional processing capabilities. ◆


Laser Power For Aluminum (Nitrogen)

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Laser Power For Mild Steel (Nitrogen)

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Figure 1. The power required to process different gauges ofA36 mild steel with oxygen as the assist gas.

Figure 2. The power required to process different thicknessesof A36 mild steel with nitrogen.

Figure 3. The power required to process different thicknessesof 304 stainless steel with nitrogen as the assist gas

Figure 4. The power required to process different thicknessesof aluminum with nitrogen as the assist gas


Systems Control, manufacturer of Boss Snow Plows, is a class-room example of successful product diversification.

Beginning in 1959 as MJ Electric, an appliance repair shop inIron Mountain, MI, the company transitioned to a nationally rec-ognized industrial and utility contractor. By 1962, then known asSystems Control, the company was a leading manufacturer ofelectrical panels and control relays.

As the company became a primary supplier to the nuclearpower industry and quickly expanded, adding an in-house fabricating shop for the cabi-nets and housings became alogical step.

“In 1973, we opened thefirst fabrication facility righthere,” says Steve Pontbriand,senior vice president at Sys-tems Control. “We recognizedthat we needed to do this ifwe wanted to get control overour own processes — our owndestiny.”

One of the early pieces offabricating equipment was aWhitney 647C, purchased toproduce the electrical cabinets.The machine, still punchingand cutting, was sold to an-other fabricating shop in 1999when it was replaced by a3700 ATC.

The stringent quality re-quirements for being a sup-plier to the nuclear powerindustry proved to be a goodexperience. The quality controls instituted for all products andprocesses provided an excellent base for other quality programsin place today.

For example, Pontbriand points out that Systems Control didn’t become ISO 9001 certified just to satisfy the industryneed. “We looked at ISO and recognized that it travels along thepath of our goals in terms of quality. We focused on buildingquality into our processes not just hiring inspectors.

“The new version of ISO focuses more on customers andprofit improvements. Companies have three years to becomecertified and we’ve got two years left…but we’ve decided thatby the time this September’s audit rolls around, we’ll be done.”

New product, new marketSystems Control began their search for an additional productwhen the nuclear power industry activity declined in the early1980s. Their capability driven search paired them with a prod-

uct quite different from electri-cal cabinets.

An inventor in Chappel, MI,had developed a unique snowplow that hinged in the mid-dle. The “wings” of the plowwere hydraulically operated.Systems Control saw similari-ties in manufacturingprocesses and opportunities.

“We looked at the plowsand said,‘Well, they’re madeout of steel, they’re paintedand assembled. There’s a smallamount of hydraulic. We cando that’,”says Pontbriand. “Sowe started in 1984. We alsosaid that if the plows are builtby Systems Control, they’regoing to have the SystemsControl quality. We were thefirst snow plow manufacturerto offer a two year warranty.”

It took about seven years tobe taken seriously. But today,

Boss is known as the industry innovator and is the third largestplow manufacturer. Continuous improvements such as a quickhook-up called the wrap attacher and custom-designed, non-glare composite plow lights are expected by customers…andcompetitors.

The plow side of the company has expanded from the initialpurchased model to a complete line of multi-position andstraight blade plows seen in every domestic snow belt.

PUNCH/PLASMA APPLICATION

Area Production Manager Dean Bauman, Senior Vice PresidentStephen Pontbriand, and Director of Manufacturing JonHarry, chose the 3700 ATC to aid demand flow manufacturing.

Systems Control Backs Into Snow Plowsand New Product SuccessSystems Control Backs Into Snow Plowsand New Product Success

Manufacturing changesThe panel business continues as a steady, year-roundbusiness. Each panel has standard features but is cus-tomized. The Boss plows, however, are sold in a six-month window from June to the end of December.The plow models are basically consistent except forthe hardware which attaches the plows to the trucks.

The plow fabrications are also from much thickermetal and, unlike the cabinets, are very hole-intense.Many of the hole intensive parts go into the under-carriage assemblies which are specific to each truckmanufacturer. Assuring that customer’s demandswould be met had the potential for parts inventorythat was not desired.

Systems Control revamped their fabricating shopprocedures to accommodate the new work flow.

“We implemented demand flow manufacturing thatbasically brings your build quantities down to one,” ex-plains Pontbriand. “We needed production flexibility tosupport that kind of demand.”

Capability expansionBy 1999, Systems Control had three laser cutting ma-chines. According to Jon Harry, director of manufactur-ing, they did a good job on the plow parts, but were too slow forthe family of hole intensive parts, particularly when you needthe “one-part” flexibility.

“We had our lasers,” says Harry,“ And the debate was whetherto buy a punch/plasma combination, a laser/punch combinationor just another laser.”

Equipment research and time studies lead them to Whitney’s3700 ATC combination with hydraulic punching and the higherpower, faster cutting TRUECut™-400.

“Our owner has always encouraged us to buy the best andthe latest,” says Area Production Manager Dean Bauman,“We

looked at the amount of laser time needed to support theseparts and chose the 3700 ATC with the punch capability and theTRUECut™-400. ”

In addition to the two major advantages — speed and qual-ity of cut, Bauman appreciated the time savings provided by au-tomatic part removal via drop door.

Since this addition of the punch/plasma, some nests whichtook 3-1/2 hours on the lasers, are produced in less than anhour. And although the three to one ratio is typical, Bauman re-ports that on certain parts there has been a production timesavings up to 80 percent.

Meeting customer needsMachine flexibility to allow “batches” of one was also a majorconsideration.

Harry says,“We have found that when peak season hits, wereact faster with the 3700 because we can get the hole intensiveparts through quicker and respond to the customer needs. Atthe beginning of the season we don’t know if people are goingto buy Fords, Chevys, or Dodges. With making the parts faster,we can react quicker to customer demand because of betterthroughput. The Whitney is a throughput machine.”

The majority of the Whitney parts are 5/16", but plate rangingfrom 16 gauge to 3/4" is processed on the 3700 ATC. About 70percent of the Whitney parts go to a press brake, and small apercent move directly to robotic or manual welding.

The production of some parts moves back and forth be-tween the lasers and the Whitney depending on machine load.


Stephen Pontbriand, senior vice president, and 3700 ATCOperator Tracy Payette, approve edge quality before sendingparts to downstream processes.

Jon Harry, director of manufacturing, inspects a row of electrical cabinets,the original Systems Control product.

Cont’d on page 22

Rough times teach us about profitability and survival. In thepast several months, those lessons have been taught again:

• During slow periods, manufacturers are apt to movework to new suppliers, looking for the lowest cost possible. Long term survival depends on the ability to sustain a competitive edge.

• To win bids, fabricatorsoften accept work for lessthan what it appears to costto man and operate ma-chinery. This is only palat-able when you know thatthe process you have is acompetitive weapon —that your competitors are reaching even further.

• Manufacturers sell products at greatly reduced prices,resulting in lower profit margins. That applies pres-sure to manufacturing and purchasing to reducecosts. When times are tough, companies that excel inOperational Excellence maintain the upper hand.

Critical knowledgeTo effectively respond during these times, fabricators need tounderstand all of their expenses, particularly the costs of owningand running each piece of equipment.

For example, we know that the costs of manufacturing partson any machine fall into one of three categories:

1. Labor costs — manning the machine. This cost is determined by the cycle time to produce parts, thehourly cost of the employee (labor and benefits) forsetting up and running the machine, and the percent-age of time the operator is at the machine while it isrunning.

2. Operating costs — expense items to run the machine.This includes consumable items (such as tooling, noz-zles and electrodes for plasma cutting, lenses and nozzles for laser cutting), repair parts, and power andgas consumption.

3. Depreciation — a lease or loan payment amortizedover the amount of work produced on the machine.The length of the loan/lease, the interest rate, and theresidual value of the machine at the end of the leaseaffect this cost. The amount of work produced on themachine also has a major impact on depreciation cost.

Determining your costsWhitney has created the Investment Advisor — a pro-gram that closely simulatesmanufacturing costs of vari-ous machine tools on a “pernest” basis. This simulation analyzes all three of the costfactors, and applies them to

real world applications. The Investment Advisor also factors inthe types of parts produced, the thickness of material, and otherhuman factors associated with any fabricator’s environment.

The process is easy (see illustration at right).

Typical resultsWe have typically found that in a general-purpose, light plateenvironment, Whitney’s punch/plasma fabricating centers offersubstantial cost savings over today’s laser cutting equipment.In many cases, this difference is as much as 20 to 30 percent!

Since the market price for fabricated parts has dropped, thedifference in profitability levels is even more substantial. Theuse of punch/plasma technology may actually be the differencebetween being profitable, and operating at a loss.

Request your comparisonYour Whitney Regional Sales Engineer will help you compareprocesses. Instead of broad assumptions, the Investment Advi-sor can provide you with a true cost analysis of your type ofwork, based on your specific information.

Arrange a no-cost, no-obligation Investment Advisor consul-tation with your Whitney Sales Representative to see whichprocess can be the most profitable for your company. ◆

An Advantage to Rough Times!The Investment Advisor


BUSINESS TOOLS

To effectively respond during these times,

fabricators need to understand all of their

expenses, particularly the costs of owning

and running each piece of equipment.

1 Provide your cost information (laborcosts, gas costs, number of shifts, etc.) 2 Determine which machines you want

to compare.

3 Choose a representative type of workfrom a variety of sample nests. 4 Provide information regarding the relative percent-

age of work in several material thickness ranges

5 Immediately see results graphicallydisplayed 6 Receive a four page report detailing

the assumptions and results

In Chattanooga,TN, a city famous for the Chattanooga Choo-Choo, Roadtec, a division of Astec Industries, manufactures as-phalt-paving equipment for building roads, not railroad tracks.These large machines are part of the Astec Industries line of prod-ucts which provide all of the equipment necessary to go “fromrock to road.” All of Astec’s seventeen divisions support road con-struction in some way. Astec’s divisions include rock crushing andconveying equipment (Telsmith, Kolberg-Pioneer), portable as-phalt plants (Astec), and asphalt paving equipment (Roadtec).

Roadtec’s products offer the latest in paving technology.Roadtec offers three types of products for the paving industry:Mills, Pavers (spreaders), and Shuttle Buggies. Mills remove ex-isting asphalt from the road and convey the removed asphalt toa dump truck (90 percent of all removed asphalt is recycled).Pavers, with standard electric screeds, take asphalt mix and lay iton the roadbed to form the newly paved road surface. ShuttleBuggies, a Roadtec innovation, are material transfer vehiclesthat bring the asphalt mix from dump trucks to the pavers.Shuttle Buggies convey the asphalt mix to the paver withouttouching it. This keeps bumps and humps from being formedand allows the paver to work continuously at its rated speedwithout stopping. A patented antisegregation design of theShuttle Buggy remixes asphaltmaterial with a consistent sizeand temperature.

Roadtec positions itself inthe market by offering un-matched customer service.According to Joe Cline, vicepresident of manufacturing,“We don’t just sell the equip-ment. We actually go out andsupport our customers, helpthem do their jobs, and sup-port them with their jobs.

“Every company should have the same philosophy as we do.Our customers are the reason we have jobs tomorrow. Some-body calls, and no matter who takes the call, we take care ofthat customer. Stop what you’re doing no matter what. That’swhat we do.”

Every employee understands this mission, and makes satisfy-ing customers the number one priority.

This mission takes us to Roadtec’s Riverside plant in Chat-tanooga, a facility devoted to after-sale support of Roadtec’s equip-

ment. In 1998, Roadtec purchased the Riverside plant to manufac-ture and distribute repair parts, and to rebuild used mobile asphaltequipment. Today, this facility not only produces parts for Roadtecequipment, but also parts for competitive equipment.

Ninety-eight percent of all orders are filled on the same daywhether for Roadtec or competitive machines. This requires a

stockroom of parts (over 9,000different parts) and a mindsetto produce parts quickly.

When the required deliveryof a repair part is “ASAP”, Road-tec satisfies that order within24 hours. When a customer’sproduct is down, Roadtec pro-duces the part to get that ma-chine running again in onlyeight hours.To accomplish this,Roadtec requires machinery

that is flexible enough to react to immediate production changes.Roadtec’s rebuild program is also housed at the Riverside fa-

cility. Roadtec takes used mobile asphalt equipment in ontrade, refurbishes and re-sells the machines for a fraction of theprice of new. Based on the original year of manufacture, the re-build price can be as much as 50 percent of a new machine.

Rebuilding equipment is a low-margin business according toCline, and therefore this start-up facility was cost restrainedfrom the beginning. There were not enough funds available topurchase new equipment, so Roadtec surveyed the market to

Roadtec Paves the Way With Rebuilt 3600 ATC


PUNCH/PLASMA APPLICATION

Whitney quickly took Roadtec’s needs and

matched them with a newly rebuilt 3600 ATC.

This machine, originally built in 1990, was

retrofitted with a new Windows NT based

CNC control, a new TRUECut™ plasma cutting

system, and at Roadtec’s request, a new

pneumatic tapping attachment.

Experienced Operator David Donohoe runs one of the 5,000different parts planned for the 3600 ATC.

see what high quality used equipment was avail-able. Because of their past success with Whitneyproducts at their main manufacturing facility,Roadtec turned to Whitney, and Whitney’s distrib-utor, Green & Associates in Chattanooga, to find agood used punch/plasma machine.

Just as Roadtec rebuilds paving equipment inChattanooga,Whitney rebuilds punch/plasma ma-chines in Rockford, IL. Whitney took Roadtec’sneeds and matched them with a newly rebuilt3600 ATC. This machine, originally built in 1990,was retrofitted with a new Windows™ NT basedCNC control, a new TRUECut™ plasma cutting sys-tem, and at Roadtec’s request, a new pneumatictapping attachment.

Did this eleven year old machine meet Road-tec’s expectations? According to Cline,“It lookedgood and surprised a lot of people. Everythinglooked like it had been taken apart and cleaned,or replaced.”

Roadtec uses the 3600 ATC to process materials from 14gauge through 3/4" thick. It processes mild steel, high strengthsteel, stainless steel, and aluminum. In all, over 5,000 differentparts are programmed and planned for this machine.

Since it is a repair and rebuild facility, lot sizes are generallysmall — averaging about 12 pieces. Raw material is stored out-side in racks, and moved into the facility immediately prior torunning. Roadtec fabricates parts out of full sheets of materialor remnants (partially used plates). If the job does not require afull sheet, the remainder is either sent back to storage as a rem-nant, or used to make “free” parts — common repair items frommaterial which otherwise would be tossed away.

David Donohoe operates the 3600 ATC. Donohoe ran Road-tec’s first Whitney machine, a 3500 ATC purchased in 1995 for themain plant, and moved to the Riverside plant when it added the3600 ATC. He takes ownership of this machine, performing regu-lar preventive maintenance such as a daily wipe down, weekly flu-

ids and punch condition check, and monthly greasing. “This machine does everything. We don’t have to drill or tap separately.We use the prick punch for layout and bending.”

According to Cline, the tapping attachment makes the tap-ping essentially free since the part does not need to be handleda second time.

And the part quality? “Certainly very good,” says Cline.“Those things are ready to go!”

While reliability and response time are important, so is holding the line on costs. Roadtec‘s tooling inventory is sparse.Tooling is stocked at Green & Associates for immediate deliveryto Roadtec’s facility as needed. Each of the 36 tooling stations istracked and stocked by Green’s office to make ordering easy.

“Roadtec calls and simply requests a punch for station 205,and I know exactly which tool they need,” says Herman Green,owner of Green & Associates.

Roadtec purchased its first Whitney punch/plasma machine, aModel 3500 ATC, in 1995, and another3500 ATC in 1997. These machines fabri-cate a high percentage of Roadtec’s parts.For example, 693 of the 1616 parts for aRoadtec Shuttle Buggy are produced onone of the 3500 ATCs. Cline notes that it is ironic that such small machines produce parts for such large pieces ofequipment.

When it comes to plate fabricating,Whitney punch/plasma equipment supports many of Astec’s divisions. OtherWhitney machines within the organiza-tion are operated at Astec (across town),Telsmith, Kolberg-Pioneer, and Carlson Paving Products. ◆


Joe Cline (left) and David Donohoe (right) show Whitney‘s Al Julian a sample of themany parts produced by the 3600 ATC.

Joe Cline, vice president of manufacturing, gives a visual image of the sizeof Roadtec‘s innovate Shuttle Buggy.

The recently introduced Whitney ADVANTAGE PrecisionPlasma Cutting Table is proving itself to be “everything a fabrica-

tor could want” in a cutting ma-chine with flexibility, versatility,and durability…a productive,heavy-duty workhorse.

New Drilling/Tapping OptionNow, a new fully automateddrill/tap option expands the ADVANTAGE capabilities even fur-ther. Six different tools are ready todrill or tap holes to 5/8" diameter.

The tubular steel (not alu-minum) bridge of the ADVANTAGEprovides the strength and stiffnessnecessary to rigidly support andprecisely position the drill/tap as-sembly for production that main-tains high precision accuracy.

The benefit to the user? Lowcost plasma cut parts with small holes in one set-up.

Whitney truly offers the lowest cost of ownership with thisnew combination.

Punching PreferenceThe 1524 CNC PrecisionPunch pairs perfectly withthe ADVANTAGE forfabricatorswho preferto punchholes. The twomachines offer plasmacut/hydraulically punchedparts at an investmentlower than the 3400 RTC,the smallest punch/plasma combination, ora laser.

One operator can easilyrun the two machinesin a continuous flowcell perfect for a just-in-time environment. The 1524 punches holes in the parts whilethe ADVANTAGE does the outlining.

Extra benefits of the 1524 include forming capabilities and the ability to punch angles with the optional Angle Iron Attachment. ◆

Introducing the ADVANTAGE … Plus!


PRECISION PUNCH/PLASMA CUTTING

The Whitney ADVANTAGE now available with the automated drill/tap option

Automated drill/tapoption

1524 CNC Precision Punch

6’ x 20’ Precision Plasma Cutting MachineLight structural custom work, contract manufacturing, retailmetal sales and rotational molds for the plastics industry are allproduced at Rivers Metal Products. Although the companythinks of itself as small — about 65 employees — its capabilitiesare numerous and surprisingly diverse.

Todd Rivers, owner, explains that a fabrication customer may bea building contractor needing a small run of base plates. Or he maybe an architect looking for custom gate decorations. Or he may bea local artist who needs a single special shape for a sculpture.

He adds that the need for parts in small quantities, with alarge amount of production flexibility, caused Rivers’ to bringtheir cutting in-house about eighteen months ago.

Mike Short, River’s president, explains,“We saw the need for acutter. First, to bring the service in-house for greater reliability; sec-ond, to give us control over costs; and third, to give us flexibilities for

5’ x 10’ Precision Plasma Cutting MachineTuttle, Inc. started out as a farm repair shop which has evolvedinto a custom manufacturer of food processing equipment.The hands-on metal fabrication background and knowledge

of Gary Tuttle, owner and president, provides the basis for thecompany’s success.

Specializing in stainless steel conveyors and equipment for thefood and pharmaceutical industries,Tuttle points out that theirjobs seldom repeat.“It’s unusual to make more than one of akind,” says Tuttle. “Even though the conveyors are sort of thesame, it seems they are never exactly alike.”

Tuttle-built products are in demand. The shop fills the pro-


President Gary Tuttle added the ADVANTAGE to streamlineproduction of stainless steel conveyors, food and pharmaceu-tical equipment.

Advantages and FlexibilityOf Precision Plasma Cutting

ADVANTAGE APPLICATIONS

The ADVANTAGE, now available from Whitney, has proven itself in a variety of shop environments. Speed, precision and a reason-able price for a heavy-duty precision machine have made it the choice for fabricators who want manufacturing flexibility, productioncontrol and reduced per part costs.

Two Nebraska companies share more than geography. Serving different markets, focusing on different types of products…butchoosing the same ADVANTAGE Precision Plasma Cutting Machine.

Cont’d on page 18Cont’d on page 18

Tuttle, Inc.Friend, NE

Rivers Metal ProductsLincoln, NE

The 6’ x 20’ cutting bed expands the length of parts offered toRivers’ customers.

duction schedulewith jobs from re-peat customers,assigning a teamto work on eachproject from thedesign stagethrough final in-stallation. This ap-proach satisfiesboth the cus-tomers and theTuttle employees.

“The peoplehere love seeing the equipment work; seeing how their productis helping the customer,” says Tuttle. When the Tuttle team com-pletes an installation, each unique product is running flawlessly.

Tuttle has done two things to keep up with demand. First, asecond shift was put in place. Second, the company hasstreamlined production and increased capacity with the addi-tion of the ADVANTAGE Precision Plasma Cutting Machine.

Many of the parts going into Tuttle equipment require severaldifferent size holes that are accurately positioned for assembly.

“We used to pro-duce parts with atape measure andpencil to mark thecenter of the holes.The cutting was ei-ther done with amanual plasma cut-ter or outsourced.Today, the high defi-nition plasma hassped us up unbe-lievably. It saves usmany, many hourson every single job.”

Minimizing fit-uptime was a key issue.When cutting the shapes by hand, any irregularities had to behandled during fit-up. Now, with parts “precision cut,” fit-up ad-justments are rare.

Ninety percent of the material processed on the ADVANTAGEis stainless, mostly 12 gauge. But Tuttle also uses it for process-ing galvanized, mild steel and aluminum. ◆

making the one-of-a-kind andtwo-of-a-kind parts in a variety ofthicknesses and materials.” Thenature of the business also re-quired the ability for quick set-up.

After researching several cut-ting methods, Rivers decidedon the ADVANTAGE PrecisionPlasma Cutting Machine. Sev-eral features were specified.

“We wanted Hypertherm, theybuild a superior product andparts and services are easily avail-able,”says Short. “We wanted atable provided by the manufac-turer — not a kit. We looked atfeatures such as drive mecha-

nisms and the integrity of the frame. We wanted a heavy build.”Size also became important largely based on parts made for

the truck mounted crane industry; many in excess of six feetlong. Grain restrictions often dictate that they be nested length-wise for cutting.

“We decided that if were going to maximize the machine, weneeded the capability for making long parts. When we don’t use thesize for part length,”Short adds,“we work off one end of the bed

with one piece of material, then run the machine down to the otherend to work a second job while we pick the parts from the first.”

After operator training and a bit of adjustment on the CADside, the machine has settled into production nicely. Materialscut on the machine include everything from 20 gauge to 5/8"plate and a good deal of high grade material. When it’s not cut-ting steel, it might be producing parts from stainless, aluminum,copper or even brass.

The ADVANTAGE Precision Plasma Cutting Machine hashelped position Rivers to respond to the wide variety of needsfrom their very diverse customer base. ◆


Owner Todd Rivers and President Mike Short searched for aplasma table offering reliability, production cost efficiencies,and flexibility.

A gate ornament from 1/8"brass and 10 gauge steel wascreated on the ADVANTAGE.

Operator Raphael Grimaldo varies fromthe typical stainless job, running 1/4"coated steel.

With Tuttle rarely producing morethan one of any piece of equipment,production flexibility is essential.

Rivers cont’d from page 17

Tuttle cont’d from page 17


A MoveFor BetterToolingProduction

WHITNEY TOOLING

A new floor layout and new location have netted new toolingproduction efficiencies for Whitney’s Punch & Die Division.

The redesign and move of Punch & Die was the next step inthe progression of implementing cell manufacturing. The cellconcept had been put into effect each time a new, more sophis-ticated machine tool increased division capabilities; but themove to a new production area allowed the smaller, independ-ent production cells and stand-alone machines to be completelyintegrated to fully accomplish manufacturing cell production.

Roger Shrum, Manufacturing Manager, Punch & Die, praisesthe efficiencies created by the move. “Whitney’s lean manufac-turing focus and dedication to maintaining tooling costs con-tributed to the decision to move. This move has allowed us tomore keenly tune all of our processes and increase production.”

For example, EDM and machining processes are positionedcloser together, facilitating material flow and greatly reducinghandling.

Queue time between operations has also been eliminated,increasing the time available for actual tool production.

With the move and Whitney’s truly integrated cell manufac-turing, Punch & Die offers efficient,“just-in-time” production andfaster turn-around for 36TC, 28XX, Structural and Ironworkertooling. These efforts are contributing to cost containment andeconomical prices for Whitney tooling customers. ◆

Join us during the 2002 Open House, April 16 and 17, for a tour of the “new” Whitney Punch & Die manufacturing bay.

Punch & Die move increases punch and die manufacturing efficiencies.Punch & Die move increases punch and die manufacturing efficiencies.

Machinist Ed Siebert checks computer data for producing shapedpunches on the weld and shape grinder within a manufacturing cell.

Operator John Lighthart produces shaped dies on a fullyautomated load/unload wire EDM.

Excessive punching machine downtime or poor partquality can often be traced to tooling problems or the machine operator’s lack of understanding of good punchand die tooling conditions.

A quick, effective way to find solutions to tooling prob-lems simply is for the operator to study the appearance ofthe punched slugs found in the slug pan and take correctiveaction. This article includes actual photographs of typicalpunched parts and slugs that can be used for comparisonpurposes to troubleshoot problems easily.

The edge condition of a punched hole (see Figure 1A) usually is very similar to that of the slug (see Figure 1B).Therefore, operators usually can use the slug, which isviewed easily, to find the cause of poor quality parts orsubstandard press performance.


Determining Punch Problems:What the slug can tell you

HYDRAULIC PUNCHING

Figure 2. Punched slugs take the shape of the punch face.

Figure 3. Punching of soft aluminumresults in a deep cut band about halfof the material thickness (1) and ashallow fracture band (2).

Figure 4. On mild steel, punchingcauses a moderately deep cut bandabout one-third of the material thick-ness (1) and a deep fracture band (2).

Figure 5. Punching of AR plate resultsin a very shallow cut band only one-eight of the material thickness (1)and a very deep fracture band (2).

Flat Face

Center Point

Concave Shear

Housetop Shear

Figure 1. The edge condition of a punched hole (A) usually issimilar to that of the slug (B).

Mild SteelThickness – 0.375" Punch Diameter – 1.000"

OA Die Clearance – 0.060" Clearance (% of Thickness) – 16%

Soft AluminumThickness – 0.187" Punch Diameter – 1.000"

OA Die Clearance – 0.024"Clearance (% of Thickness) – 13%



AR PlateThickness – 0.250" Punch Diameter – 1.000"


A B

1 2 1 2 1 2


Operators and maintenance per-sonnel first must understand how anormal slug should appear underideal operating conditions to deter-mine if a tooling problem exists. Anormal appearance depends on thetype of punch being used (such asshear on the punch face to reducetonnage requirements) and the typeand hardness of the material beingpunched. The slug’s appearance cangive the operator clues regarding:punch shape,material type,dieclearance,punch and die misalign-ment,and punch and die wear.

Punch ShapePunched slugs take the shape of the punch face, reflectingsuch punch characteristics as flat face, centerpoint, concave

shear, and housetop shear (seeFigure 2).

Material TypeType and hardness of the materialaffect the cut edge condition.Punching of soft material such asaluminum (see Figure 3) results ina deep cut band about one-halfof the material thickness, as wellas a shallow fracture band.

On medium material such asmild steel (see Figure 4), punchingcauses a moderately deep cut band about one-third of the ma-

terial thickness, as well as a deep fracture band.Punching hard material such as abrasion-resistant (AR) plate

(see Figure 5) results in a very shallow cut band only one-eighthof the material thickness, as well as a very deep fracture band.

Die ClearanceMachine operators gen-erally have control overthree variables that can either give excellent results or cause prob-lems: amount of dieclearance, punch and diealignment, and punchand die wear. Howthese variables are con-trolled produces eitherexcellent results orcauses problems.

Figure 6. When the upper and lowerfracture lines meet, a clean hole isproduced with a minimum powerrequirement.

Figure 7.With insufficient clearance,the two fracture lines do not meet,leaving a ring of material that must bestressed again to the point of fracture

Figure 8. Excessive clearance betweenthe mating edges causes extremeplastic deformation (1), a large burr(2), and a high angle of fracture (3).

Mild SteelThickness – 0.375" Punch Diameter – 1.000"OA Die Clearance – 0.060" Clearance (% of

Thickness) – 16%


Thickness) – 3%


Thickness) – 25%

Recommended Clearancesfor Short-Run Punching

% OVERALL CLEARANCE

MATERIAL Minimum Best Maximum

Copper, 1/2 Hard 10 13 16

Brass, 1/2 Hard 10 13 16

Mild Steel 12 16 20

Steel 0.50C 12 16 20

Aluminum, Soft 10 13 16

Stainless Steel 12 16 20

Table 1. Recommended clearances for short-runpunching increase with the hardness of the material.

Die diameterBurr Punch diameter

Clearance on one side

Figure 9. Punch and die misalignmentproduces varying edge conditions such asthis burr.

Figure 10. Sharp burrs result from dullpunches. A dull die produces similar burron the punched part.





1 1

23

Cut Band

Cut Band

Fracture

Fracture

Sharp Burr

Cont’d on page 22

Whitney introduces new tooling inserts to help you reduce your tooling costs!Now available for most shapes up to .750", the inserts punch with the same accuracy, durability

and flexibility as the full bodied tooling at considerably less cost.The pin and slot system aligns your tooling at any angle for reliable, repeatable accuracy.

Both standard — 0° and 90° — and special orientations are available. Simplyremove the holder’s positioning pin to use standard rounds.

Insert benefits include:• Savings of 50% or more• Accurate and flexible positioning for shapes• Durability in standard tool steel or HSS (your choice)• Easy size identification etched on radius

If you have questions or need more information contact your local Whitney distributor, visit online at www.wawhitney.com, or contact DavidWhite, Tooling Sales & Marketing Manager at 815/490-0321 or via email at [email protected].

New Tooling Inserts Save Money

WHITNEY TOOLING


In most cases when a problem exists, incorrect die clear-ance is the cause. Most companies have several dies with dif-ferent clearances for each punch, and it is up to the operatorto select the right clearance that will yield the best results.

The quality of the punched hole is greatly dependent onthe amount of clearance between the two opposed cuttingedges (punch and die). The appearance of the slug tells theoperator if the clearance needs to be adjusted.

On the slug, the upper and lower fracture lines shouldmeet; if they do, a clean hole is produced with a minimumpower requirement (see Figure 6). Recommended clearancesfor short-run punching are shown in Table 1.

With insufficient clearance, a characteristic known as sec-ondary shear is produced. The two fracture lines are unableto meet, leaving a ring of material (see Figure 7) that must bestressed again to its point of fracture with a further expendi-ture of energy.

Excessive clearance between the mating edges causes ex-treme plastic deformation, a large burr, and a high angle offracture (see Figure 8).

Punch and Die Misalignment and WearWhen the punch and die are misaligned, various edge condi-tion problems can result from side to side (see Figure 9). Ifthe problem is severe enough, tooling is damaged.

Worn punches and dies produce large burrs on the slugand the punched part (see Figure 10). ◆

Punch problems cont’d from page 21Systems Control cont’d from page 11

That also adds toshop flexibility.

What’s next?Within the next twoyears Systems Controlis planning a expan-sion to the 150,000square foot facilitywith a new officebuilding and manu-facturing bay. Andanother new product

“We need anotherproduct that iscounter-seasonal tothe one that we haveright now,” says Pont-briand. “A productthat will maximizeour facility and ourpeople.”

Looking four yearsahead, Systems Control plans to be double the presentsize. As far as the snow plow end of the business,“We’ll bethe biggest and the best.” ◆

About 70 percent of parts fromthe 3700 ATC go to downstreamprocesses which include bendingand robotic or manual welding.

❑ Yes! I would like to continue to receive my free subscription.

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Total number of employees at this location: ❑ 1-49 ❑ 50-99 ❑ 100-249 ❑ 250-499 ❑ 500-999 ❑ 1,000+

Fabricating equipment at this facility: (check all that apply)

❑ Punch/Plasma ❑ Lasers ❑ Flame Cutters ❑ Turret Presses ❑ Single Station Punching Machines

❑ Press Brakes ❑ Shears ❑ Ironworkers ❑ Saws ❑ Welders ❑ Portable Presses ❑ Angle Rolls ❑ Other:

Signature: Date:

Fax to 815-964-3175 or Mail to: Becky Edmundson, WMFN, P.O. Box 1206, Rockford, IL, 61105March 2002

See Whitney ProductsAt Our Open House

April 16-17, 2002use the form above to register

Register for Whitney‘s Open HouseFax to 815/964-3175 or register via web site at www.wawhitney.com

I’ll be there ❑ Tuesday, April 16 ❑ Wednesday, April 17

Arriving about a.m/p.m Arriving about a.m/p.m

Name Title

Company

Address

City State Zip

Country

Phone Fax

E-mail

The following Team Members will join me:

1)

2)

3)

I/We will attend the following seminars:

New Manufacturing Technologies for Increasing Profitability

❑ 10:30 a.m., Tuesday, April 16 ❑ 10:30 a.m., Wednesday, April 17

Reducing Costs via Material Utilization

❑ 1:30 p.m., Tuesday, April 16 ❑ 1:30 p.m., Wednesday, April 17

W.A. Whitney Co.AN ESTERLINE COMPANY

The PartHANDLER™-II brings the efficiencies of

a fully integrated material handling system to

Punch/Plasma Fabricating Centers — on a

smaller, affordable scale, with cycle times that

match the world’s most productive process for

plate — punch/plasma.

Programmable magnets automatically load plate, then sort

and place completed parts onto skids or into carts.

The PartHANDLER-II fits snugly to the left-hand side of the

machine virtually eliminating the need for added floor space.

The skeleton drop table combines with the machine on the

right-hand side to complete material handling benefits,

again without the loss of valuable real estate.

Add the PlateSTORE™ option for

integrated, automated material

selection via CNC control.

Efficient, affordable, fully

integrated, plate handling

automation — that fits.

From the Leader in Plate

Technology.

Streamline plate handling

operations for your Whitney.

Several solutions are available

for your Punch/Plasma or

PlateLASER™ products.

For more information about

the complete line of W.A. Whitney

fabricating centers and cutting

tools, contact us at 650 Race

Street, Rockford, Illinois 61101.

Phone 815-964-6771. Fax 815-964-

3175. Or visit us online at

www.wawhitney.com.

ThereThere’s Always Room fors Always Room for

AutomationAutomationThere’s Always Room for

AutomationAt least there is with Whitney’s newPartHANDLER™-II Automation System.

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