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TTM

Your Laser Solution

Magazine

Number 10 - 2016 - House Organ issued by TTM LASER

your

laser solutions

Four chucks with loading gantries: the winning combination!

This issue of the TTM Laser Magazine is

entirely dedicated to laser systems for 3D cutting of TTM Laser tubes and profiles. It has the widest range of tube laser systems in the world, designed to cover sizes ranging from 20 mm to 815 mm in diameter with several models and options. FL 600 3D installed by Laserjet in Vicenza, for example, features tube loading and unloading gantries. This is a real innovation which the customer preferred over the more traditional automation with manipulators and chains.

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eliability and modularity are typical of TTM Laser tube cutting systems.

The FL 300 3D model we're talking about is a real example of the modularity of these systems, loading with a chain and unloading with the Cartesian gantry.

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flat laser cutting system that is perfectly integrated into user production lines, thus making the production process easier and more efficient. This is the challenge that TTM Laserlaunches on the market with its TL 312 3D model.

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SL 2.5-25 is the code of the automatic laser cutting and welding system commissioned by the Indian Railways for the production of entire side and roof bodywork panels for their new passenger wagons.

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Four chucks with load the winning combinati FL 600 3D installed by Laserjet in Cagnano di Poiana Maggiore in the province of Vicenza features tube loading and unloading gantries. This is an innovation chosen by Lino Fraron, owner of the company, preferring it over the more traditional automation with manipulators and chains.

“N Lino Fraron, owner of Laserjet Group, inaugurated the new wing of the factory where the FL 600 3D is installed by throwing a big party and inviting customers, suppliers and workers.

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o one ever came up with this type of solution" states Fiorenzo Castellini, Chairman of TTM Laser. "The FL 600 option of loading and unloading with manipulators and chains remains, but for the Laserjet, the customer chose the configuration which best met the need of being flexible even while machining considerably larger tubes".

Laserjet is the leader of the Laserjet Group, which includes another important company, Energreen, which manufactures lawnmowers for large areas used, for example, for public gardens or motorways. "They were not present in the tube world and they wanted to enter through the front door by purchasing the FL 600 3D� says Castellini.

"Though being a service centre which obviously subcontracts, part of its work is dedicated to meeting the structural needs of Energreen. That links them to a host of industries, especially agriculture, where being able to process large tubes is fundamental". The choice of FL 600 with Trumpf 5 kW laser source was not made randomly since agriculture makes use of many tubes ranging from 88.9 to 610 mm (from 3.5" to 24") in diameter. It is a great advantage to be able to offer customers a full-service, by flanking sheet-metal processing with tube laser cutting at these diameters.

Working with the maximum possible flexibility Initially Mr. Fraron saw the machine with the chain loading. But his doubts vanished when TTM Laser proposed the solution with gantries, which have the big advantage of enhancing machine flexibility, both when loading and unloading.

"The loading gantry allows to position tubes of any size (as long as they are within the range to be machined) in the order I want. You are no longer forced to follow the order they are placed in to machine them, as, for example, the chain system where the positioning of the tubes is binding" explains Mr. Castellini. "All of this - he continues - guarantees greater flexibility especially for those companies with frequent production changes like, of course, a "subcontractor", where there are many lots but all in all quite small. And perhaps this is the reason why Mr. Fraron hap-

pily greeted the alternative to the chain. The same holds for the tube unloading phase where the option of managing and handling them conveniently without the risk of dropping them is fundamental due to their size and weight (max.

290 kg/m - 194 ppf. Here again the cut tube can be taken and placed as you wish. For example, I can stack them up or I can put smaller pieces in a basket using a manipulator. There are several options in the unloading area covered by the gantry, greatly increasing the flexibility of the system".

The logic comes from an analysis made regarding the times of a laser machine, where, in the case of sheet metal cutting, the process phase is predominant, while the loading and unloading phases are secondary. It is exactly the opposite for tube cutting. There are long idle times while the tubes are being handled and the cut-

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ading gantries: tion!

ting phase is quite brief with respect to the loading times. In tube laser cutting, the source is active for 30/40% of the time due to this type of issue.

"We thought a lot about these aspects and decided to greatly lighten the problems regarding the loading and unloading of tubes" adds Fiorenzo Castellini once again. "Operations which, among other things, are done while the machine continues working thanks to the presence of four chucks managing the tube which guarantee the utmost functionality and reliability of the process".

"The combined effect of having four chucks with gantries makes the plant extremely efficient".

"We're still searching for the concept of the maximum productivity for these large dimensions,

minimizing the time of the loading phases, which is where we can still act to make the system even more efficient and flexible. This type of machine implicates a rather large investment. This is why it must absolutely be productive and TTM Laser has taken the path of developing solutions like the one installed by Laserjet and why, from the very beginning, we designed our plants to be modular and customisable according to the specifications of each customer".

The first time on big format The one installed by Laserjet is not the first installation with gantries manufactured by TTM, as we already boasted of past experiences, but regarding smaller machines, namely the FL 300 3D. In this case, it was the first time that the gantry

solution was coupled to such a large tube cutting machine such as the FL 600 3D. This is why TTM Laser upgraded and evolved the same concepts, adapting them from a dimensional standpoint and enhancing the option of gripping the workpiece using either grippers or fingers depending on whether you want to take the tube by diameter or by its ends, which is very convenient to unload tubes by clamping them one to another.

Each gantry has two gripping arms independent from each other: this makes it possible to work with just one arm if the tube to be loaded or unloaded is particularly short. There are over 40 axes at work in this type of plant, where the solution for short pieces (up to 800 mm - 32") has also been foreseen, setting up a conveyor belt and tipping unload skip.

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A question of range FL 300 3D is the concrete example of the modularity of TTM systems, being equipped both with chain and bundle loading and unloading with a Cartesian gantry.

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t is a machine designed to process tubes ranging from 20 to 305 mm (from 0.75" to 12") in diameter. One important feature is therefore the wide cutting range. “FL 300 3D is our flagship product with over thirty installations. The inspiration at the base of this model - explains Fiorenzo Castellini - is that of offering high performance in a relatively small cutting machine.

This means that it has been designed to process the light tube with impressive performance as well as the heavy tube with high level performance since the machine has been developed to work continuously and reliably".

"In my opinion, it is the ideal machine for subcontractors who want to approach the general industry with their services, metalwork in general and, why not, the structural pipe and civil construction sectors which are practically unexplored in Italy. Our competitors also propose machines for these industries but, unlike ours, they have been designed to respond to the needs of two precise sectors: the furniture and automotive industry. It's the same machine updated, with the diameter of the

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Reliability, modularity and customisation are the basic features of TTM tube cutting systems.

you do not follow through with the rest of the machine.

If the intention is that of approaching the heavy tube market, a solution must be designed from the start for this type of issue and any of our machines, even the FL 300 3D which can bear a maximum weight of 60 kg/m (40.3 ppf), is built to meet this type of need".

The best configuration for individual needs

chucks slightly increased and a 3D head installed. We don't think that's enough because the market requires a solution which, from the start, can quickly pass from cutting a bundle of 20 mm (0.75") diameter tubes to one to one 305 mm (12") tube even 12 m (41') long.

It is not enough to simply widen the chucks if

"The fact of having designed it to be modular comes from the awareness of not being able to expect that every customer will buy the full optional version of the machine" states Castellini. "The basic concepts remain the same and therefore the machine is always productive, but it can only be made more efficient with some loading and unloading options and an obviously higher investment Our strength is the option of being able to customise FL 300 3D to real working needs, just like the larger systems in the range, because we designed the machine in a modular fashion from the start so that it could be configured to each customer's needs.

There are multiple solutions to customise machine unloading, ranging from the simple 6,500 mm (21') unloading bench to 8 or 12 m (31' or 41') benches with third chuck, or again 12 m (41') bench with third chuck and Cartesian gantry.

It all depends on what the customer wants to invest in and what he expects from that investment. Among other things, from now on, the new FL 300 3D version will be equipped with a hole tapping and flaring unit, thus further enhancing it with other options which allow you to completely finish the workpieces".

FL 300 3D was created in the 6,500, 9,500 and 12,500 mm (21', 31' and 41') version with bundle and chain loading (the two solutions can be combined). Standard tube unloading can be done simply on the mobile tilting table, this is also in 6,500, 9,500 and 12,500 mm (21', 31' and 41'), or by adding a third chucks which obviously makes it possible to process better by also supporting heavier pieces.

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A quality certification

The ideal mix

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L 400 3D is a machine capable of processing the so-called “structural tube” without any problems. It has greater capacity than the FL 300 from a performance standpoint as it can cut diameters ranging from 40 to 406 mm (from 1" 1/2 to 16"). Clearly if you predominantly process tubes up to 200 mm (8") in diameter, FL 300 3D is the ideal machine. But if the most frequent cutting requirements are linked to diameters beyond 250/300 mm (10" / 12"), then FL 400 3D is the best choice.

These two types of machine are very much alike, but the extra 100 mm (4") diameter which “400” can process makes the difference, as the machine was designed and structured appropriately, without being limited to less efficient choices such as the use of tracks (which for example are used from FL 600 and up). In fact FL 400 has mobile chucks on slide benches which allow it to move at 80 m/min (262 ft/m). Furthermore FL 400 inherits the use of four chucks from FL 600, already being able to handle rather heavy tubes and profiles (max-

imum weight born 140 kg/m (90 ppf). This must not be underestimated considering the advantages it provides. This again makes it possible to load the new tube while the machine keeps on working just like “600”, or to unload the machined tube while the machine is already cutting the next one.

FL 400 3D is sort of an ideal mix between FL 300 and FL 600, as it inherits the machine concepts used for these two models.

“At TTM Laser, a name does not identify the machine, but rather a wider concept of plant which we sew onto the specific requirements typical of the industry which we address following a very clear and linear logic. I can say, without fear of contradiction, that with such a vast and complete range we definitely have the solution for any type of tube cutting need and for any production environment" says Fiorenzo Castellini, Chairman of TTM Laser.

“The concrete example of what I just said continues Castellini - is the FL 400 3D machine installed by Siderpress in Modena, a very active service facility in the field of metalwork and semi-assembled supply for the earthmoving, agriculture and telescopic crane industry for which the dimensional range of our machines provides a flexibility and freedom of movement beyond compare. Among other things, the use of a Trumpf 4 kW source makes it possible to easily cut the high resistant steel beams used for the telescopic booms on the cranes.

In 2004, Siderpress was one of the first companies who put their trust in us for laser cutting systems for flat sheet metals, which is why the FL 400 3D installed is a sign of the ongoing relationship of reciprocal trust and respect which has clearly been profitable for both sides. Siderpress is a sort of quality certification of our plants”.

FL 400 3D is the intermediate model between the two machines we have looked at so far. From a performance standpoint, this system can be compared to the FL 300 3D, while it enhances its options by being able to process a wider range of tubes both as far as diameter and thickness are concerned. Though it does not compete with the larger FL 600 3D from which, however, it inherited some important structural concepts such as the use of four chucks.

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Structural build OFFMA of Udine has got us talking about FL 600 3D again, the machine installed by this company from Friuli, to cut open structural profiles, such as “IPE”, “C” and “L”-shaped profiles intended for structural building.

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hat is particular about this installation are the choices OFFMA made. Aware of wanting to approach the issues of a certain segment of the market, and therefore, above all, needing to cut industrial profiles instead of tubes, they preferred to aim for a traditional chain load and unload automation but which fully met its needs. This once again confirms the enormous possibilities of TTM Laser systems in terms of layout and configuration.

"Since they have more serial work - Marcello Filippini, Technical Manager of TTM Laser explains - they are able to exploit the potential of a loading chain to the maximum, setting up the sequence of profiles to be cut in a targeted fashion. Then, in the specific case of OFFMA, we're talking about a company having its first experience of laser cutting in gen-

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eral and so I would like to emphasise not only the marketing work of the plant, but especially the considerable training and instruction work which we are still doing to accompany them on their way to exploit the system to the full. And this is among the most demanding applications there is, needing to cut open profiles, though by now it is a standard operation which is easy to program and manage when passing from one process to another. In fact you can easily switch from cutting a rectangular section tube to a “C”- shaped tube without any particular problems, but rather with the advantage of not needing to change the piece gripping jaws".

An ad hoc extraction hood The FL 600 3D machine installed by OFFMA features a maximum sustainable load of 290 kg/m (194 ppf) and the option of cutting diameters ranging from 88.9 to 610 mm (from 3.5" to 24"). It is also equipped with a 5 kW CO2 laser

Since OFFMA has more serial work, they are able to exploit the potential of a loading chain to the maximum, setting up the sequence of profiles to be cut in a targeted fashion.

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source and its aesthetic and functional aspect has been improved. In this case, TTM Laser refurbished the livery of the machine, equipping it with a new cutting fumes extraction hood because the basic principle of open profiles is different as the fumes can no longer be suctioned by the chucks. Therefore open profiles require a powerful extraction hood to be set up in the cutting area, leading to the installation of the new cabin to gather the fumes and not to release them into the environment.

lding is served

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s has already happened in the past with the adoption of the 3D cutting head as a standard supply for each system, with which TTM Laser anticipated the market standard, this time with the use of four chucks, the company from Cazzago San Martino is using facts to convince users of the need for this type of solution, especially in structural tubes where it is essential and absolutely winning.

FL 800 was designed by taking into account the need of completely finishing the pieces mounted on the machine to reduce idle time regarding management and recovery of pieces considering their enormous dimensions. Therefore from the start, the machine was equipped with a flaring and tapping head and seats for recessed screws. Furthermore, like FL 400 and FL 600, the head and tail chucks are equipped with a floating system so that long tubes do not undergo mechanical and torsional stress which, in the long run, can wear down the mechanics of the chucks themselves. “We're continuing on the path taken about eight years ago - explains Marcello Filippini - when we thought about things and decided to equip all our machines, except the FL 300, with four chucks, the first and last of which are floating. We deem this an essential aspect which, for example, allows it to process with the head 90° to the side of the tube, to go back up and to perform concentric machining on the other side, and therefore in axis with it, without needing to rotate the tube. This provides an absolute guarantee of cutting precision despite the fact that the tube could be slightly bent by its nature. To guarantee precision, you must not move the tube but it's the machine which must rotate around it. This is a fundamental prerogative for TTM Laser�.

"We were pioneers on some concepts - continues Filippini -and we still are, as we strongly believe in the validity of our solutions. For obvious reasons, machine construction costs are higher than that of our competitors, but we are sure that the price is justified by the validity of the solutions offered and the reliability of

The Top

FL 800 3D is the flagship of the TTM range, as well as the largest tube laser cutting machine in the world. Equipped with loading and unloading gantries and four tube handling chucks, except for FL 300 3D, by now it is a consolidated standard for every TTM plant. the process. These choices in construction are essential for the type of product. TTM Laser has developed the FL 800 3D because we are convinced that the industry needs to process tubes of this capacity and size (diameters ranginf from 150 to 815 mm - from 6" to 32" weighing a maximum of 350 kg/m - 235 ppf).

Perhaps this requirement is not yet that clear and widespread due to the lack of knowledge about the existence of this type of dedicated technology, but it has a bright future in view of

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its undeniable and evident advantages, especially in the structural tube, oil & gas and petrochemical field, from which rather interesting requests have already arrived".

Manufacturing from the user's standpoint A very important aspect of TTM Laser's constructive philosophy is definitely linked to the fact that, before being manufacturers, they've been users of tool machines for over 60 years.

They therefore have a background and culture at their shoulders which considerably and positively affect their conception of a machine that does the utmost to meet the requirements of the market, and to even anticipate future needs, which is what happened for example with the 3D cutting head, the option of loading the machine both by bundle and by chain, and, they are convinced, this will happen with gantry loading. Nothing is coincidental and everything that is made is designed through

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of the range

The machine is equipped from the start with head and tail chucks with a floating system so that long tubes do not undergo mechanical and torsional stress which, in the long run, can wear down the mechanics of the spindles themselves.

the eyes of the user who can exploit the potentialit y of the machine to 110%. It is not by chance that the very first FL 800 3D model will soon be installed by Laserway, namely the subcontracted tube cutting service centre with which TTM Laser has a partnership agreement. This has the dual strategic objective of testing and seeing with our own eyes the reliability of each cutting solution developed, having installed the entire range of TTM tube laser systems, and of allowing TTM Laser cus-

tomers (as well as Laserjet and OFFMA) to immediately start to explore new markets by offering subcontracted cutting services, without having yet installed the system.

"This is a big advantage for the customer who, once the machine is installed, can already open up new channels establishing itself on the market with a technology which it did not have before, with a host of cutting programs developed by those who run the system at its maximum and provide excellent training of op-

erators who will immediately be able to exploit the machines to the utmost" affirms Marcello Filippini, Tube&Flat Division Sales Director of TTM Laser.

"We are therefore an out-and-out reliable process partner capable of supporting customers in every stage of use of the system.

We want our customers to be ever more convinced that they are installing our product because it is innovative, functional, better and reliable. But also because by choosing TTM Laser they acquire a full-fledged technological partner capable of following them in the development of applications, especially those which require use of machinery they are not equipped with.

To be clear, with its partnership with Laserway, TTM Laser intends to improve the concept of the service centre, allowing its customers to cover 360째 outsourcing cutting requirements, even for those jobs linked to tube cuts for which they are not equipped directly, but which, through the services of Laserway, they can still accept and satisfy".

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Laser cutting that s A flat laser cutting system that is perfectly integrated into user production lines, thus making the production process easier and more efficient. This is the challenge that TTM Laser launches on the market with its TL 312 3D model. A fast, sturdy and functional machine designed from customer requirements and focused on consolidated business experience in manufacturing laser cutting systems.

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L 312 3D represents innovation as opposed to our traditional concept of flat cutting: instead of having a dual carriage to support the cutting source, we now have a single portal. We have succeeded in obtaining an application, which we think is unique, in which the cabinet has been divided in order to make it lighter. In a nutshell, we have tried to make a large-sized, high performance cutting machine.” The introduction by Fiorenzo Castellini, owner of TTM Laser, is the most effective way to launch the new flat laser cutting system developed by the company, which is based in Cazzago San Martino, Brescia. A system de-

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signed from an essential task: accelerating the customer's work by means of customised machines to meet personal requirements. “When designing our machines, we try to fulfil the expectations, requirements, and layouts of our customers. Unlike other manufacturers that have more pressing standardisation requirements, we highly respect our customer's requirements, not only in terms of cutting but also with regard to distribution of space and time management. More operations carried out, which means the machine is more useful for daily work, is translated into a better return on investment”, adds Davide Rebessi, Sales Manager of TTM Laser.

A logic focused on return on investment Whoever purchases a sheet laser cutting machine must focus on the machine's performance and technical features, but must also consider its incorporation into the production site and the benefits it can offer in terms of logistics and reduction in downtimes. A broad vision focused on return on investment requested when purchasing. “Machines are often supplied on reasoning that is totally dissociated from their application and the way they are used”, explains Castellini. “In fact, customers do not always consider the questions linked to logistics, which are important and can save on resources,

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The TL3123D model is designed as a large-sized, high performance machine.

Under. When designing the new model, TTM Laser has focused on more than ten years of business experience in the production of tube and sheet cutting systems.

t simplifies life The TL3123D model is designed as a largesized, high performance machine. The end part of the laser cutting system used on TL 312 3D is based on the cutting head designed by Precitec.

A system composed of mobile hoppers to provide more efficient suction.

especially for those processing large amounts.

We maintain there is still a lot to do and much to develop with logistics: companies do not often consider this aspect much, instead, it is very important. Return on investment can relate to better competitiveness, performance and improved

logistics: all advantages we are able to guarantee as a result of the system we have designed.”

When designing the new model, TTM Laser has focused on more than ten years of business experience in the production of tube and sheet cutting systems.

The end part of the laser cutting system used on TL 312 3D is based on the cutting head designed by Precitec.

Development of the new laser cutting system TL 312 3D forms part of this context. “It is a machine with many workstations that enables processed piece unloading and loading of a new piece”, says the owner of TTM Laser. “A compulsory operation, unless the machine is equipped with a dual pallet. We have tried to enable the operator to unload the pallet and slowly pull out the pieces he requires from the cutter. Once scraps are unloaded, the empty pallet can be loaded once again with sheet metal pieces. It is a concept that is focused on better production and improved logistics.”

The technical features of TTM Laser TL 312 3D also derive from ever-increasing current market demands. “We have focused on a general increase in performance in terms of speed, tolerances, and positioning when designing the machine”, says Davide Rebessi. “In addition to wider cutting dimensions, we have also designed two possible unloading areas on both sides of the machine with a mobile pallet system to transport them to other areas of the building, also during the machining process.”

The pallets are placed on rectified guides.

Maintenance required on the motors, helical guides and other elements is thus significantly

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reduced. Use of 3D laser cutting technology also enables better quality since the machine bevels during the cutting phase. Masking is thus avoided since the laser's precision is used to pre-assemble the pieces before proceeding with welding.

The pallet change structure can be simplified To meet customer requirements, the pallet change structure of the TL 312 3D model can be simplified, even if the standard model still has a traditional pallet change. Since the pallets are transferable, the new version can interest those who need to unload pieces onto a different bay from where the machine is installed: in this case, loading will be on one side and unloading on another, and the machine is in the middle. “Pallets usually have a two-way flow adds Fiorenzo Castellini - however, it can be modulated according to requirements. In fact, at times customers expressly ask for a wider belt, even up to 5 m, in order to insert two sheets next to each other.”

Davide Rebessi, Sales Manager, summarises the production logic adopted by TTM Laser. “A machine like the one described here can be considered perfect compared to performance permitted by small-sized laser cutting and size benefits of 'old' systems characterised by larger sizes and wider loading spaces.”

Also in the case of the TL 312 3D system, thicknesses that can be processed mainly depend on the type of laser used.

The importance of experience in tube and sheet laser cutting TTM Laser has always been specialised in manufacturing tube and sheet laser cutting systems.

Specific experience, which, when designing innovative systems, is fundamental. “Laser has always been our goal”, states TTM Laser's Chief Operating Officer, Eng. Filippini. “We believe that designing laser cutting systems is what we know how to do”.

Castellini recalls: “The first ever 3D head we assembled was over 10 years ago. Today, we are the only tube laser cutting manufacturers using 3D fibre”.

When purchasing a sheet laser cutting machine, you must consider its incorporation into the production site and the benefits it can offer in terms of logistics and reduction in downtimes.

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Use of 3D laser cutting technology enables better overall quality since the machine bevels during the cutting phase.

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When purchasing a sheet laser cutting machine, you must consider its incorporation into the production site and the benefits it can offer in terms of logistics and reduction in downtimes.

According to Davide Rebessi, TTM Laser's Sales Manager: “More operations carried out, which means the machine is more useful for daily work, is translated into a better return on investment”.

Use of 3D laser cutting technology enables better overall quality since the machine bevels during the cutting phase.

According to Davide Rebessi, TTM Laser's Sales Manager: “More operations carried out, which means the machine is more useful for daily work, is translated into a better return on investment.”

The rapid development of the fibre laser cutting technology has revolutionised the industry, making it easier (perhaps too easy) to cut sheet metal. “Certain operators appear on the market convinced that they can use fibre laser for cutting operations without having the appropriate instruments”, argues Filippini. “Especially in difficult times like now, those investing in a machine should weigh all the factors at risk. Instead, others risk running into nasty surprises by investing in solutions that seem affordable, but which clearly show their negative aspect when they are faced with many problems and have no assistance. Basically, introducing fibre technology has undoubtedly simplified things. However,

it also distinguishes the difference between those who simply see it as a business opportunity and those who, by contrast, rely on the passion and experience in developing new solutions. I have reason to believe that the gap between those who work passionately and those who run a business is perceived by customers. For example, our customers visit us, see how we work, and how the business is doing: they appreciate us because they know us.”

Accessing new markets to continue developing Considering what has just been said, we ask Fiorenzo Castellini to tell us about the good results obtained by TTM Laser. “TTM is consolidating itself and continues growing. In order to increase production, we will soon be moving to our new premises, which will enable us to make use of an area approximately five times larger than the current one. In terms of results, TTM increased its turnover by 20% last year, and this

year we still plan on increasing it a further 20%.

Expectations are important and ambitious.”

As part of the company's strategy and as confirmed by the owner of TTM Laser, flat cutting is committed to taking on increasing importance.

“We still perform many more tube cutting operations than flat sheet cutting, however, we are strongly promoting the latter since we will shortly also have the fibre version, always in 3D: we believe this is an area to focus on. We predict a revival of flat cutting, especially with large dimensions. Our past experience enables us to access a market that is able to welcome new protagonists by designing functional machines that are primarily fast and operational. In fact, we want the machine to outlive the laser: we hope that whoever purchases a machine today can change the laser in thirty years' time without having to change the machine.”

Also in the case of the TL 312 3D system, thicknesses that can be processed mainly depend on the type of laser used.

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TSL 2.5-25 is the code of the automatic laser cutting and welding system commissioned by the Indian Railways for the production of entire side and roof bodywork panels for their new passenger wagons.

Laser cutting and welding t

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Internationally, they are known by their English name, Indian Railways, which is one of the biggest companies in the world, with a rail network of more than 60.000 Km and over 18 million passengers and 2 million tons of freight traffic per day. On its rail network of 63.327 Km, Indian Railway runs more than 200.000 wagons and 50.000 carriages pulled by more than 8.000 engines; it also runs 6.909 stations and has over 1.400.000 employees, which makes it the third biggest employer in the world after Walmart and the State Grid Corporation China.

Fully finished side and roof panels Indian Railways is another prestigious name in TTM Laser’s client portfolio, from whom it commissioned an innovative TSL 2.5-25 automatic laser cutting and welding system for the production of side walls and roofs for its passengers wagons. This is an avant-garde system designed and customized by TTM Laser to the client’s specifications. TSL stands for “Taglia Salda Lamiere” ( sheet cut and weld), 2.5 indicated the maximum weld length, equal to the maximum sheet width for the application (2.500 mm), while 25 indicates the maximum length in meters of the parts the system can handle. The system outputs complet-

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ed semi-finished parts, since it not only produces a sheet size which is almost impossible to find in the market (2.500 x 25.000 mm) but also processes them to produce finished wagon side walls and roofs, including the openings for doors and windows.

Perfectly orthogonal edges and zero burrs This project certifies TTM laser as a provider of genuinely customized, dedicated systems, characterized by exceptional reliability and ease of use . The XL format of the

side walls and roofs, depending on what has to be produced, is obtained by trimming and welding together multiple 2.500mm wide sheets of variable lengths, to produce the final product ( roof or side wall). The operating cycle is very simple: once loaded, the first sheet is centered and moved into the welding area to wait for the second sheet which is loaded, aligned and moved into the same area.

The two sheets are then trimmed by laser to ensure that the edges are perfectly orthogonal. Once this has been done, the two sheets are moved to the zero gap position, which

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g train side walls can only be done if there are absolutely no burrs ( which would compromise the weld)since the weld fuses the two edges together. This ensure uniform mechanical characteristics of the material since no filler is used, and makes a geometrically invisible weld, since the joint does not affect the thickness of the material, which remains constant even across the weld. Note that all welding procedures have obtained certification by Indian Railways, who have subjected our samples to stringent testing. These include traction, folding, hardness and fatigue tests, micrography, mechanical abrasion and corrosion tests. Once

the first two sheets are welded together, the resulting sheet is moved forwards until the trailing edge reaches the welding area where it is joined with the third sheet, which has been loaded and aligned in the meantime. A third weld is now made and the cycle repeats the number of times required to manufacture the final format. This means that to create a 24m side wall, 12 sheets (25.000x2.000 mm) must be welded together, requiring 11 laser trimming and welding cycles.

The special characteristic of the TSL 2.5-25 is that, every 6/8 m of welded product, the joining cycle is interrupted by a phase in which the sheet is shaped and the door and window openings are cut. The gantry hosting the capacitive head moves into a cutting area adjacent to the welding area and shapes the entire side wall or roof.

Once this phase is over, the gantry returns to the welding position and adds a further 6/8 m of sheet before running a new shaping cycle. This cycle is repeated as many times as required to obtain the finished part. Before the new welding cycle, a second gantry running on the same rails as the first, equipped with suctions grippers, collects the larger offcuts resulting from the cutting cycles and stacks them on pallets. Smaller offcuts are cut into the smaller pieces during the cutting cycle itself, and then offloaded and scrapped by a conveyor located under the system’s bed. Note that the operating cycle of the TSL 2.5-25 is fully automatic as the cutting and welding settings are also controlled by the machine’s PLC unit.

The operator is thus only responsible for loading the raw sheets, starting the cycle and supervising the system’s operation. The Indian Railways TSL 2.5-25 is equipped with a 3500 W CO2 laser, but the system can be equipped with any type of source, including fiber optic lasers, given the minimal thickness of the parts being processed. In this particular case, the sheets are 2/3 mm thick in stainless steel.

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Göcke doubles u Göcke Umformtechnik Gmbh, a company based in Germany that specialises in the creation of special products and productions for the transport industry, has decided to redouble its productive capability by buying a second TTM laser cutting and welding system: a TS 5.12 for producing sizes of sheet metal that are not available on the market.

ust as in a game of poker, there are those who fold when facing “critical” situations in the working world, allowing themselves to be dragged down by events, and those, on the other hand, who raise and double up. In short, there are those who face up to and act upon a static market, often by making courageous choices that to many may seem hazardous. This is the case of Wihelm Göcke, who together with his son Jörg, manages Göcke Umformtechnik Gmbh, a company specialising in special products and productions for the transport industry, that has decided to redouble its productive capability by buying a second laser cutting and welding

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system for producing sizes of sheet metal that are not available on the market. Yes! This is precisely what Göcke specialises in; moulding products in an unexceptionable and fast way, according to the unusual sizes and dimensions that it obtains from joining smaller sheet metals, and trimming and welding them together with the most innovative laser technology.

Reinvesting to grow again It was in 2007 that the Göckes, father and son, decided to invest in a TTM Laser TS 4.20 fully automatic system, which has the capacity of producing semi-finished sheet metal of large dimensions, as used in the transport industry, es-

pecially in the rail industry. It is no coincidence that in 2010, with this system, TÜV NORD granted the company UNI EN ISO 15085 certification for welding processes within the rail industry.

The system is introduced into an automatic line for the construction of carbon and stainless steel body sides, with a thickness of between 1 and 8 mm, for urban transport. The system installed

by Göcke uses a stationary positioned Trumpf TLF5000 as its power source. It automatically trims and welds, crosswise, sizes of up to 4m in width and 20 m in length, with extremely fine seams that are not prone to shrinkage.

“Offering innovative solutions for all sizes means having to constantly update production” explains

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up

The TS 4.20 automatically trims and welds formats of up to 4 m in width and 20 m in length, with thin seams that are not prone to shrinkage. The TS 5.12, on the other hand, allows for the creation of sheets with a maximum width of 5.000 mm and 12 m in length. This machine is not limited to welding sheets of the same size; it also allows for the easy joining of different width strips, of different materials and thickness, thereby allowing for the construction of made-to-measure sheets, limiting the maximum weight and increasing the resistance capacity of the finished product.

Mr. Göcke. “We work with a modern machine park which is constantly reorganised and renewed according to the most up-to-date technical standards. We make a constant effort to always be innovative. This is the reason behind the choice made in 2007, and the one made now. Even back then, the growing request for large format welding lead us to making a quick decision: to either give a quantity of orders to external entities or to keep them internal, investing in a new laser cutting and welding system.

In substance, the decision to install TS 4.20 was the classic “make or buy” choice: we outsource work or in the future we also want to carry out production internally according to our high qual-

ity standards. The volume of orders has increased notably since we decided to invest in this kind of system in order to move in new directions. We hope, as we are also convinced, that the same thing will also happen with the new TS 5.12, thereby shifting our market and enabling it to recommence in the right way. If we hadn’t installed the TS 4.20 in 2007, the crisis of the last few years would most definitely have hit us harder and permanently. Instead, the choices made have meant that we have only been slightly affected. However, today we wish to go back to growing and the choice of TTM LASER’s TS 5.12 is the means for us to move in this direction.

Laser longitudinal cutting and welding Unlike the TS 04.20, TTM LASER’s TS 05.12 is a fully automatic line for producing large formats with different thicknesses, and this best fulfills the production needs of Göcke Umformtechnik Gmbh. The TS 5.12 can join sheet metal of different materials and thickness up to 12 m in length, longitudinally. The system’s typical applications are the longitudinal welding of sheet metal with high mechanical properties, among which, for example, sheets of highly resistant steel.

The TS 5.12 system loads two or more sheets of metal, of up to 12 m in length, automatical-

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ly and can combine several trimming and welding procedures in order to obtain various different semi-finished product configurations, between them also joining several sheet metals with different lengths, widths, materials and thicknesses. The accurate mechanical design of this system has also allowed for transport on the main cart of the CO2 Trumpf TLF5000 power source.

The basic idea behind this machine concept is that of creating formats that are larger than those produced by previous accessories. In fact, the TS 5.12 allows for the creation of sheets with a maximum width of 5.000 mm and length of 12 m. The machine is not limited to welding sheets of the same size; it also allows for the easy joining of different width strips, of

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a different material, as well as a different thickness, thereby actually permitting the construction of made-to-measure sheets, limiting the maximum weight and increasing the resistance capacity of the finished product. The latter is in fact an important factor, above all in the transport industry, where the trend is increasingly more emphasised on and aimed at reduction in weight, which is equivalent to a decrease in consumption together with an increase in the resistance capacity necessary for addressing the issue of high velocity in the rail industry. The TS 5.12 therefore allows for the automatic feed of strips with a minimum width of 600 mm and a maximum of 2.600 mm, welding them together until the programmed sized sheet is obtained.

A finished and guaranteed product One of the outstanding novelties introduced by this new machine are the process control methodologies and certification of the finished product. One of the recurring problems with these products is actually the inherent quality of the welding. TTM LASER has done some important work in this direction and, thanks to the machine concept which foresees the use of two laser tests, the TS 5.12 offers, for the first time, welding process control systems together with a non-destructive control which certifies the product in a definite and guaranteed manner.

For the real time quality control of the welding being carried out, the TS 5.12 is equipped with a system that is able to read the principal physical parameters of the welding process, such as the

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[ TTM LASER offers pure laser welding processes without filler material; the ideal solution for esthetically high quality weldingwhich reduces thermal deformations to a minimum. It is also capable of incorporating hybrid welding processes, from the L-GMAW (laser-MAG) to the L-GTAW(laser-TIG); both highly indicated when a high degree of variability is expected in the joint geometry, as well as for specific hardness requirements.

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CERTIFICATION ACHIEVED The devotion, reliability and professionalism that distinguish TTM LASER Lasr, together with the important results that they constantly obtain, are guarantees of maximum quality and complete trustworthiness. The Quality Certification, in compliance with the UNI EN ISO9001:2008 standards, that TTM LASER was granted by TUV , is proof to this.

the sheet metal, certifying the quality.

It is therefore evident, thanks to the introduction of these two control systems on the machine itself, that the standard of welding is guaranteed, with the possibility, in the event that accidental factors have caused non-conformity, of immediately taking the sheet metal and repeating the trimming and welding process in order to deliver a finished and guaranteed product.

Joint detection, size and tracking

temperature of the molten baths, the formation of plasma and the amount of reflected light. These readings are constantly elaborated and compared to readings stored in a technological data base. Any deviation in the readings taken, in respect to the standard reference of average readings, is analysed by software which automatically determines if the welding carried out is satisfactory and that the quality is constant.

However, in several cases and for specific sectors, this is still not enough. Many clients

are often asked for the certification of the product and for this reason welded sheet metals must undergo non destructive controls (NDT) after welding with obvious movement problems and therefore of time and cost. TTM LASER has therefore incorporated an ultrasound control system (US) to the machine which, when asked, provides a scan of the entire seam as soon as the machine has finished its welding cycle, registering the parameters on a file that can then be given contextually to

TTM LASER incorporates sensors into its welding systems in order to track, in real time, the joint and off-line mapping of the same through the use of a coaxial chamber mounted on the weld head or else with external laser sensors.

The reconstruction of the trajectory is then entrusted to a numerical elaboration of the image that is managed by the central controller. The use of extremely fast real-time hardware, such as FPGA or multiprocessor systems, guarantees the computing power necessary for the analysis of large amounts of data.

For very stringent applications, where it is necessary to precisely evaluate the geometrical characteristics of the joint before welding (position, significant presence of even very narrow gaps), TTM LASER has developed a mapping software based on high precision biodimensional laser triangulation, in order to scan the shape of the profile in a direction orthogonal to a weld line. In this way, the system is able to modify, fully automatically, the theoretical trajectory of the welding used as far as the actual positioning of the piece is concerned and to immediately alter the main process parameters (laser power, welding speed and the amount of filler material) for the actual sizes of the joints.

It is also possible to install the PUSH-PULL wire feeding system, which guarantees maximum performance in terms of the precision and speed of response of the feed speed control system.

Special applications, such as the wobble system (oscillating mirror) and twin-spot optic systems can also be used. The use of these solutions arises from the need to widen the beam transversely to the welding direction, or to preheat the material.

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In the new site By the end of this year, all the activities of the Castellini Group will be transferred to the new Teze production site. This way, Castellini, TTM Laser and Laserway will be located in the new 21,000 m² plant. The building is entirely constructed in steel with parts cut mainly using TTM machinery. This new establishment will make it possible to implement an even better reorganisation of the activities and to allot spaces inside the structure for Research & Development.

Laser welding machines will also be available in view of being ever closer and attentive to the needs of the customers. The new site will give the entire Castellini Group an image, which up until today was not possible due to lack of space.

A more appealing image which is more fitting and in line with the level of technological innovation which characterises the business of each company, with TTM

Laser at the head. "We need to organise ourselves to be ready to make the most of the future opportunities which the market offers" affirms Fiorenzo Castellini, Chairman of the Group. "It was important for us in the first 10 years to create a brand,

The latest addition to the range is already a success L170 3D Fiber is the final piece in the 3D TTM range of tube lasercutting systems. A machine equipped as standard with a high brilliance laser source and a 3D cutting head, a combination that makes it suitable to process any type of material including highly reflective ones, such as copper, aluminium and brass round, square or open-section tubes.

FL170 3D Fiber combines high productivity and flexibility with low consumption and low operating and maintenance costs typical of solid-

F

TTM LASER S.p.A. 25046 Cazzago San Martino (BS) Italy Tel. +39 030 7256311 Fax +39 030 7256333 info@ttmlaser.com

www.ttmlaser.com

to develop the technology we have and to form a large, innovative and enviable product range. But the time has now come to further fortify this brand with a prestigious site which demonstrates the technological concepts linked to the structural tube we have been proclaiming for a long time".

state lasers. The system is equipped with 21 controlled axes, including the automatic tube loader with a length from 6.5 to 12.5 m and the unloading system, which is automated for tube sections with a length between 2 and 6 m. The load capacity ranges from 12 to 168 mm in diameter in the case of round tubes or from 15 x 15 to 120 x 120 mm for square-section ones. The 150 m/min linear speed of the two fitted spindles makes it a particularly high performing tube-cutting system.

FL170 3D Fiber once again shows how TTM Laser, thanks to its expertise in laser technology and its applications in the field of cutting and welding, is a privileged partner able to offer products and meet the needs of any customer.

Associato UCIMU - Sistemi per Produrre