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TTM
Innovation & High Technology
TUBE TECH MACHINERY
Magazine
Issue no. 4 – October 2009 – Six-monthly magazine published by Tube Tech Machinery
Between flat cutting and work centre I choose lasertube The FL 250 3D Evolution installed by Marelli Aldo can work “small” but its main strength is machining large sizes. The plant has several distinguishing characteristics, the most outstanding of which are the tube bundle-loading system that can load 12 meter long tubes and the Cartesian unloading system that allows you to stack tube crops as long as 8 m onto pallets in an orderly fashion.
hanks to the lasertube, Kägi has changed its role from being merely a tube retailer to becoming an actual partner who provides a service to its customers: finishing the tubes according to their specific needs. The systems installed are an FL 400 3D and an FL 250 3D.
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he new TS 5.12 of Tube Tech Machinery is ideal for trimming and welding sheets having nominal dimensions of up to 12,000 x 2,500 mm and thicknesses from 1 up to 8 mm to obtain large finished metal sheets having a maximum size of 12,000 x 5,000 mm.
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Between flat cutting and work centre, I choose lasertube
The FL250 3D Evolution with a 12 m load and an 8 m long Cartesian unloading system is the solution chosen by Marelli Aldo to expand and complete its offer in the field of third party realization of metallic carpentry. An important choice that "winks" to the structural tube sector.
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stablished in 1979, Marelli Aldo is the marriage of professionalism, entrepreneurial skills, know-how and experience in the field of metal structural work. From single pieces to small and large production series, the company owned by Figino Serenza in the province of Como can meet any type of sheet metal or metal tube machining needs and supply a finished product of absolute, also aesthetic, quality. In its 30 years of business, Marelli Aldo has investigated and examined the production problems of every setting and sector – from simple metal fences to more complex structures and metal structural work for machine tools – and accordingly increased its capabilities to meet the urgent and sometimes extravagant production needs for interior furnishings. These challenges are a real proving ground for a third-party processing company. Design decisions, often remote from real technological possibilities, found a ready response in the mastery and production and engineering capabilities of the company as demonstrated by the futuristic reception of a hotel in Rimini and drawing tables made for prominent designers.
Targeted investments policy The growth of the company went hand-inhand with the continuous and wise process 2 TTM - TUBE TECH MACHINERY
of technological renewal of the machine fleet installed in a shed having a surface area of 3,200 m². And perhaps it was in this setting more than anything else in which the entrepreneurship of Aldo Marelli emerged brilliantly. Along with his son Stefano, he carried forward a policy of targeted investments aimed at continuously improving the service offered to its customers. “The goal of every investment is to be able to give something more”, says Aldo. “And thereby expand our range of action by starting to satisfy even the requests we previously could not accept”. Proof of this is the industrial thermosetting powder painting plant installed in 2001 to provide our customers with a truly “finished” product. “We set ourselves the goal to set up a painting plant that would guarantee high-level quality and service, to enable customers save time and avoid incurring additional costs” explains Marelli. “After conducting some analysis we believe that the best direction for today was a thermosetting powder painting plant, suitable for steel, sheet-metal and zinccoated parts. Moreover, thanks to the optimal quality/price ratio, this type of painting is suitable for a multitude of commodity sectors, from large-scale facilities to interior design and technical lighting
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The “smart” Cartesian unloading system allows you to stack single tube crops up to 8 m long onto pallets in the adjacent area of the system.
design and offer optimal resistance characteristics.” Therefore targeted investments are important but so is farsightedness, as in the case of the laser flat cutting system installed in early 2004. It provides a work space of 2,000 x 4,000 mm and laser power of 4,400 W. This allowed Marelli to start working right away, even on considerable thicknesses. And in doing so it distinguished itself on the market and rose above the conventional “price wars” typically found in thin sheet metal.
“Small items” but mainly large sizes The same farsightedness and entrepreneurship in early 2009 led Marelli to install an innovative lasertube, by Tube Tech Machinery, which allows it to process tubes having a diameter of 15-300 mm, as well as bars and profiles with a square section as large as 220 x 220 mm and rectangular sections as large as 250 x 100 mm. Therefore we are talking about a machine, the FL 250 3D Evolution, that can work “small” but its capability on large size is what distinguishes it, further proving the
intention to stand out on the market in relation to those who Aldo prefers to consider, because of his philosophy, colleagues and not competitors. “The time had come to take another step forward and make another leap in quality for the company”, Marelli continues. “Having a 40% increase in turnover as the result of introducing the first flat laser, we were initially tempted to purchase a second system. However we quickly decided not to take that route because it would have added little in terms of “giving customers something new”. We thought about purchasing a work centre that would allow us to do in-house machining operations to remove the chips; however, currently we are still outsourcing this operation. So there you have it! We had been fascinated by the potentialities of applying laser technology to the three-dimensional cutting of tubes and bars. A lasertube would have allowed us to exploit the skills we had already acquired by using a laser and in so doing significantly expand market outlets. More importantly, we could pass on several advantages to our customers since we could now conceive and study the metal structural work in a new
Marelli is able to process tubes with a diameter of 15 up to 300 mm, but also square bars up to 220 x 220 mm and rectangular sections of 250 x 100 mm.
way. Building structures with tubes and bars cut in 3-D makes it possible to achieve “daps” that used to be unthinkable before. They would also be better and optimal in terms of performance and resistance. It would reduce the need to weld the structure which now can simply be “fastened” in a few spots. This means having even higher precision in the metal structural work with higher quality in the machining operation at a lower cost because it minimizes the worker-machining of residual material. The Marelli FL 250 3D Evolution is equipped with a max. 12 m long tube-bundle loading system.
Unloads tubes as long as 8 m in an orderly fashion The FL 250 3D Evolution installed at Marelli Aldo is the concrete expression of the capabilities of Tube Tech Machinery to personalize its systems according to specific production needs. “We chose this plant mainly for the purpose of the machining of medium large parts, though in the initial phase small diameters are more prevalent” Marelli explains. “It is our intent to emerge in the field of structural tubes and this is why we opted for a versatile and flexible plant, having a CO2 laser source of 3,200 W. There is no doubt that we stand out from others because of the configuration chosen, because the machine has a 12 m tube-bundle loading system, a third spindle that makes it possible to pick up and machine even the last crop while another tube is being loaded. Moreover there is an innovative Cartesian system that unloads “intelligently” in the adjacent area for the stacking of each individual tube crop, up to 8 m long, onto pallets. This aspect is vital because it allows you to unload the tubes in an orderly fashion and find them practically ready for packing and shipping without having to go over them one by one. This translates to wasting less time, increasing productivity and lower processing costs which becomes a direct benefit to the final customer. This advantage is even more significant when handling large heavy tubes”.
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] The lasertube has a revolutionized the way Kägi manages its work which increasingly uses lasers even for simply cutting tubes or sheets to size.
3D CUTTING
Semi-finished and finished tub Kägi is a Swiss company with a long history of selling tubes that – contrary to what one might think due to its over 100 years of company history – is an eminently dynamic business that is evolving all time. Several years ago it took the decision to reinvent itself and go beyond being merely a tube retailer to becoming an actual partner who could provide a service to its customers by finishing finished tubes according to specific requirements.
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ägi has always worked in the sale and distribution of metal tubes and profiles. Being equipped only with conventional cutting lines (circular saws) for cropping and cutting tubes to the requested sizes – solutions that recluded to perform the finishing operations on the tubes – the company long ago intuited the possibility of being able to better “serve" its customers by supplying tubes that were already finished with notches and anything else required to improve and facilitate their use. Kägi is very familiar with the machining of tubes and therefore knows that it requires several specializations. The sectors and settings where it is used are vast and extremely diversified. This awareness suggested laser cutting as the most suitable technology for this purpose. So it found in the FL 400 3D system made by Tube Tech Machinery the ideal solution for its needs. A fundamental aspect that characterizes the strategic move made by Kägi was its willingness to process a certain size of tubes, while thinking about the possibilities of processing medium-to-large diameters to distinguish itself from to its competitors already present on the market. This is why they chose an “intermediate” plant from the Tube Tech Machinery range. “Though still a work in progress, the FL 800 will bring lasertube performance up to levels never reached in the past", says Alessio Cadei, Sales Manager
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of the Brescia company”, We currently produce three plant sizes: the FL 250, the FL 400 and the FL 600. The FL 400 3D chosen by Kägi is the intermediate size. A size that allows it to approach the small-tube market, i.e. approximately 40 mm, as well as large diameters of up to 406 mm, with any type of section: round, square, oval, modelled or an open profile that can be inscribed in the maximum diameter according to the initial intentions of Kägi. We are one of the few manufacturers who offer such a wide range of machinable diameters”.
More rapid and higher precision assemblies “Kägi found in our technology a basic strong point”, states Cadei. “The use of the 3D cutting head mounted by Tube Tech Machinery on all of its machine models, even the smallest, demonstrates this. Our “3D” is not an optional. In fact the machine is equipped right from the start with this type of head. I could almost say that the “2D” is the optional in this situation. Upstream of all it is an important awareness. The world of tubes is evolving and companies who embrace the lasertube will not be making an anachronistic decision but will be going beyond the immediate situation at hand. Bear in mind that tomorrow, companies might have the need to make bevels, partial cuts and even other machining operations that the 3D head will allow them to make safely and econom-
ically. It will no longer be required to re-machining the piece which is such an expensive step of processing because it requires suitable locking equipment and machinery (different for each article). Moreover much less time is needed than in the past”. One of the basic strategic elements in the continuous growth of the lasertube is precisely the possibility to make complex structures in the simplest possible manner thanks to the daps you can obtain by fully exploiting the potentialities of laser cutting. “The possibility to use the 3D cutting head”, adds Cadei, “allows the designer and engineer to come up with solutions that until now have been unconceivable, and that bring huge advantages in terms of assembly. Assemblies are quicker and more precise and, furthermore, sturdier and more economical”.
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[ Perfect alignment of tube under head The 3D head was certainly one of the aspects to which Kägi gave priority. Another decisive factor was the machine configuration with four mobile spindles that make it possible to “mask” all the dead times associated with handling the tube and as such they do not affect the production cycle. As the cutting operations are carried out the tube goes from spindle 1 to spindle 2 and then to 3 and 4 and while the last machining operation of the tube end segment is being finished, the new tube can be loaded and prepared for cutting; the machine is immediately ready to cut without having to wait any time at all for unloading. “The technology of the four spindles contains multiple functionalities to avoid mechanical problems, or any kind of problem for that matter, especially in the handling of tubes with large diameters and thicknesses that, by their very nature, are never perfectly straight” explains Cadei. “Often they are subject to “bends” that must be managed properly to avoid damaging machine parts. This is why spindles have self-centering and selfloading systems designed to compensate for the geometric errors of the tubes and at the same time ensure the per fect alignment of the tube under the cutting
twice as fast as the typical speeds for machining tubes of these dimensions.
Personalized Lay-out Another aspect that should not be overlooked, and that in the case of Kägi was given extra care, was the personalization of the entire plant, even in ter ms of its layout. The optimal management of the handling of tubes, whether rough or cut, is only apparently secondary but it is essential when we are talking about tubes having lengths up to 14 m that weigh a few tons and are extremely cumbersome to move around the shed. We therefore established with Kägi the ideal flow for rational machining of the tubes; this means that an incredible amount of care was given to the starting position of the rough tube and where it is more
A P P L I C AT I O N S
Finished semi-manufactured parts, even those with a small diameter
The four-spindle
The lasertube is becoming an increasingly strategic choice for companies who process sheets but want to expand their business to include similar sectors as well as for companies like Kägi who want to supply finished products in addition to cutting tubes to size. Therefore the decision to invest in an inter mediate machine was the right decision because it allowed the Swiss company to position itself on a market segment that has not yet been covered, i.e. that of large tubes. And it also allowed them to see and experience the potentialities it provides for sectors that use small tubes.
functions that are
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technology feature designed to avoid mechanical problems, or any type of problem for that matter, especially in the handling of large diameter tubes which, by their very nature, are never perfectly straight.
Currently, in spite of the number of competitors, the largest volume of work is for medium dimensions and medium-small dimensions. This is why Kägi, after purchasing the FL 400 3D, wanted to add a second lasertube and has even started talking about a third machine. “This would be an FL 250 3D and the clear goal would be to supply customers who need very small tube diameters, even smaller than 20 mm, up to a maximum diameter of 300 mm with lengths of 8,500 mm” explains Cadei satisfied. “Consequently they chose a slightly smaller type of machine but again
be according to specifications
head. The tube might be crooked but the machine can manage it without damaging itself and, more impor tantly, while maintaining the precision of the cut. The spindles can function independently or can be connected as a gantry function”. Summing up the three basic aspects in Kägi's decision, we need to firstly mention the possibility of covering an extremely wide range of machining operations, as the well-established possibility of making 3D cuts and, most importantly, the plant productivity and flexibility because in all handling operations of tubes while the machine is running, productivity becomes truly unrivalled. The increased productivity is also associated with the increased basic speed of the axes that move the machine. In fact we are talking about a machine equipped with linear motors that run on the main axes at 100 m/min, in other words
convenient to “come out” with the processed tube to achieve an appropriate flow to the production cycle and ideal for positioning of the plant “utilities” (laser source, electrical board, etc.) that have been arranged in such a way as to not hinder the work process. “Kägi wanted a raised platfor m on which to position electrical boards, the suction plant and the laser source so that the space on the ground could be dedicated to other components of the plant” specifies Cadei. “We are talking about a total length of over 40 m by 16 m, with a 14 m long “loading” and “unloading” stretch.
Optimal suction of fumes The plant installed by Kägi respects the work environment and the workers. The automated handling of tubes significantly reduces the risks to human safety, as well as the cutting fumes suction system which is always present inside the tubes. There are two suction systems, one on the right edge and the other on the left. This guarantees optimal suction of the fumes produced by the cutting even during the final assembly of the last tube crop. A suction device alone would not make this possible and would significantly pollute the air in the workshop. Tube Tech Machinery ensures maximum suction in a work situation, with noticeably positive effects on work safety and worker health.
did not want to give into the “laws of the marketplace” that simply require the classic machine for 2D tubes having a diameter of 6 m. In these cases the 8,5 m 3D tube with diameter up to 300 mm is machined in a flexible way, closed and opened profiles thanks to the chain operated front loading system. This new machine manages tubes having a linear weight of 45 kg/m, in other words its performance is decidedly high”. As we have seen, the laser tube has revolutionized Kägi's work management in a way that increasingly exploits the laser even for simple operations of cutting to size. The fact of also being able to use the lasertube for cropping operations, and program them easily and rapidly, certainly represents an additional oppor tunity though Kägi's primary reason for installing the Tube Tech system was to supply finished tubular semi-manufactured products.
The 3-D cutting head was one of the decisive factors for choosing the FL 400 and 250 cutting systems.
The FL 400 3D cutting system is installed at the Kägi factory.
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Tube Tech Machinery has presented the new TS 5.12, the latest sheet metal welding plant developed by the company after its fortunate experiences with the TS4.20. The machine is capable of trimming and welding sheet metal with nominal dimensions of up to 12,000 x 2,500 mm and thicknesses ranging from 1 up to 8 mm to obtain finished sheets having a large-size, with maximum dimensions of 12,000 x 5,000 mm. This is a solution that makes it possible to think of welding different thicknesses of sheets to obtain “Tailored Blanks”.
Tailored Blanks … … no problem
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he TS 5.12 has a remarkable degree of automation that, starting with the rough sheet fed manually, allows you to align and centre the sheet by alternating longitudinal and transversal movements on rollers provided with a safety clutch. After centering the first sheet, it is locked with an automatic hydraulic blank holder stop and then trimmed using the laser cutting head. Simultaneously with the trimming of the first sheet, the machine brings the next sheet to the proper position, aligns it and centres it until the final trimming phase. After trimming the two adjacent edges of both sheets, the machine brings them closer to each other and welds the edges continuously with the laser head and without deposit metal. A US welding control system is provided during the entire process. These phases can be repeated in automatic mode until the formation of a sheet having maximum dimensions of 12,000 x 5,000 mm.
The TS 5.12 cutting and welding system will be ready for the first tests and inspection trials at the beginning of 2010.
A fibre laser of 4 kW One of the most important new features of the TS 5.12 is certainly the use of the fibre laser. For the first time, Tube Tech Machinery is ready to use a fibre laser resonator (4 kW) made by IPG Photonics with the certainty that after conducting in-depth trials and multiple tests, is today the best solution for welding without deposit metal. Another point of interest of this new TS 5.12 is the possibility to be able to start with sheets made from coils, appropriately prepared. This reduces costs of raw materials
XXL LASER WELDING Producing large sizes from small standard sheets is the specialty of the transformation technique used by Göcke in Ahaus. Its TS 4.20 laser plant made by Tube Tech Machinery automatically welds sizes of up to 4 m wide and 20 m long. The beads are extremely thin and do not shrink. The TS 4.20 welds small sheets to make large-sized sheets; they purchase the sheet sizes found in regular stores – small, medium and large – and weld them to make them into small plates that can reach the abovementioned dimensions. Thanks to the laser technique, even very thin sheets can be joined without deforming them and this is a great advantage. The plant processes sheets that are 1,5 – 8 mm thick. “We keep an individual solution ready for every request”, says Jörg Göcke, the director and son of the company's founder. “Since we are specialized in special productions, we offer the best possibilities for rapidly and impeccably welding the products ac-
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cording to size or unusual dimensions. One of our distinctive strong points is the large size which can be as much as 25 m long. These pieces are used in building bridges, vehicles or open air excavations”. So Göcke in Ahaus produces machined parts for the mining of lignite or half-octagonal shells for the construction of current or electricity poles for the procurement of energy. Another important application for Göcke is the construction of wagons for the metro trains, urban rail trains and regional railways; for the wagons of local traffic it produces whole sheets of stainless steel for the lateral walls that are solid, lightweight and trimmed.
which benefit the cost of the final product. Moreover the possibility to make metal sheets to size (Tailored Blanks) allows them to “build” a metal sheet with variable thicknesses to reduce the weight of the sheet and provide the resistance capacities required. This factor also contributes significantly to cost reduction while improving the quality of the product. The machine will be ready for the inspection as early as January 2010.
Growth has facilitated the decision Offering innovative solutions in all sizes means having to continuously update production. “We work with a modern fleet of machinery that is continuously reorganized and renovated in accordance with the latest technical standards,” says Göcke. “Our ongoing aim is to be increasingly innovative”. So, the growing demand for large welded sizes has confronted us with a choice: do we outsource a certain volume of the orders or keep them in-house and invest in a new laser welding plant? “The decision to install the TS 4.20 was essentially the classic “Make or buy" decision. It was up to us to decide: should we outsource this work or do we want to provide this production in-house according to our high quality standards? The volume of orders increased so much that over time we decided to invest in this TS 4.20 automatic laser welding plant. Another reason for our decision was the desire to embark on new ventures”.
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New TECHNICAL DATA Maximum loadable tube length Maximum tube weight Tube sections
The cutting operations are also automatic To complete the range of machines that cut and weld metal sheets, Tube Tech Machinery is developing new solutions that also integrate the laser cutting technology for the realization of finished pieces. In addition to the TS4.20 and TS5.12 lines, we are currently designing a solution that allows the preparation by welding the large sheet and later, on the same machine, subjecting it to all the laser cutting operations -- completely automatic -- to produce the finished product. These are usually specific customized plants, therefore designed to solve very specific problems. In particular this type of machinery has applications for situations where huge sizes need to be made, e.g. the edges of train wagons and metro cars. The goal of the new plant is to weld sheets using a laser head without deposit material and therefore to make the cuts that will constitute the windows and doors of the aforesaid wagons in automatic mode. One of the main advantages, besides the notable speed of the process, it is the remarkable savings in the handling of the sheet that in these cases can be as large as 4,000 x 25,000 mm for making double-decker carriages. The machine will be able to start with standard sized rough sheets and pre-assemble the large size and cut it. It will then use an integrated handler to unload the sheet directly from the machine into the position stipulated by the customer. The new plant will also have a system for automatically unloading the offcuts which are large since we are dealing with wagon windows (approximately 1,500 x 1,000 mm): these offcuts will automatically be stacked on pallets and then made easily available to be reused on other laser cutting machines.
Dimensions rally section maximum Dimensions square section (maximum) Dimensions rectangular section (maximum) Maximum unloadable tube crop
FL 800 3D 16,000 mm 350 kg/m round, square, rectangular, oval 815 mm 550 x 550 mm 600 x 400 mm 16,000 mm
FL 800 moves the challenge ... urrently Tube Tech Machinery already has the broadest and most complete range of lasertube plants and produces three different machine sizes: FL 250, FL 400 and FL 600. However the new FL800 is currently being created, and is a solution that will raise the bar even higher in terms of maximum machinable diameter, the real “challenge” for lasertube manufacturers. In addition to being able to process large diameter tubes, this new machine will embrace a fresh concept for moving them. In fact the plant will have air portals for loading and unloading and therefore will enable the precise and rapid management of heavy tubes. The portals will be managed in a simple and intuitive manner by the CNC and will not require a change in set-up when changing the type of tubes.
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Synergy “We can also produce customized metal plates”, Göcke continues, “the so-called Tailored Blanks, to make a large sized sheet in various thicknesses and of different materials or types of steel. An important advantage of TS 4.20 is the automatic control of the welding bead. Here the machine controls the three values of pliability, temperature and luminosity of the product. From this we can figure out the quality of the welding bead. As long as these three values stay within the established tolerance field, the welding bead is considered good. If any defects occur, the plant continues to weld its initial program until the end. Then there is a visual control by the welding control unit. If the defects are found, such as pores or inclusions, the entire joining process is repeated, in other words the weld is cut and welded again.
The visit of Alessio Cadei, the Sales Director of Tube Tech Machinery at the Trumpf location in Ditzingen confirmed and further strengthened the close collaboration between the two companies. The meeting made clear the organization and quality proposed by the German company with whom it was reinforced the strong partnership so that it is not unilateral, i.e. supplier-customer but it makes possible to engender more effective synergies developed jointly.
IN PIACENZATO TALK ABOUT Lasers and Aluminium “The welding of aluminium: new prospects offered by modern laser technology”. This was the theme dealt with at the opening discussion at EXPOlaser 2009 (19 - 21 November) with the contribution of Tube Tech Machinery and IPG Photonics and major Italian universities such as the Milan Polytechnic and the University of Brescia. Welding aluminium with laser technology is a topical issue that is spreading widely through the world of light alloys, especially in light of the advent of innovative fibre laser resonators. Performance and operative flexibility are wedded with premium mechanical characteristics making possible the application of this technology even in fields that till now have been predominated by conventional welding methods. This is why the afternoon Conference of Thursday 19 November is something you will not want to miss.
Alessio Cadei, Sales Director of Tube Tech Machinery (to the right) and Costantino Pizzorno of Trumpf.
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EMO 5.-10. October 2009 - Milan I Hall 18 - Stand B14
ube Tech Machinery will soon blow out the ten candles. It is celebrating its tenth anniversary during an extremely difficult and problematic macroeconomic context in which so many companies are floundering. Nonetheless T.T.M. increased its turnover by 5% in 2008 and the forecast for 2009 allows to confirm the same turnover as the previous year. T.T.M. recently assembled a “Tailor made” brochure showing its range of machinery and plants, including the latest inventions. I really like the idea of “the smallest company with the broadest range of laser machines for processing tubes”. In this market segment we offer solutions that can machine tubes with diameters of 15 mm and even reach 800 mm, all using the 3-D cut. In these plants we have introduced (and once again, we are proud to be the first) “intelligent” unloading portals. This solution is achieved by using controlled axes and inventions that can generate significant increases in productivity estimated at around 20 30%. All of this is done in absolute safety, bringing an improvement to the work environment which, as you know, is now an added value as well as a regulatory obligation. In December we will present the new TS 5.12, the plant for cutting and welding different sizes of sheet metal, whether it is carbon steel or stainless steel, with a work field of up to 5000 x 12,000 mm. The generator will be Fibre Laser 5000 W made by IPG Photonics. We will concretely have a way to verify the performance and characteristics of the laser at a high brilliance level. This technology, highly anticipated on a market that has high expectations, will be tested by T.T.M. and compared with the CO2 laser. We believe it will represent an enormous step forward in the world of applications, even though, like all things that must be tested in all possible situations. Therefore, in spite of these difficult years for the economy, in 2008 and especially 2009, T.T.M. continued to persevere undaunted in its process of growth and research of new applications.
A constant growth EXPOlaser 19.-21. November 2009 - Piacenza I
Blechexpo 1.-4. December 2009 - Stuttgart DE Hall 1 - Stand 1521
Tube Tech Machinery S.r.l. Via Bonfadina, 33 25046 Cazzago San Martino (BS) Italy Tel. +39 030 7256311 Fax +39 030 7256333 info@tubetechmachinery.com www.tubetechmachinery.com
associate UCIMU - SYSTEMS TO PRODUCE