Product category:
CNC laser cutting and profiling machines
News Release from: LVD (UK) | Subject: Impuls and Helius laser profiling machines
Edited by the Manufacturingtalk Editorial
Team on 20 July 2000
Laser cut parts break new ground in car
production
Two LVD laser profiling machines, an LVD Shape punch press and two LVD multi-axis press brakes are used at Park Sheet Metal of Coventry on work for the new Lea Francis 20/230 sports roadster
Two LVD laser profiling machines, an LVD Shape punch press and two LVD multi-axis press brakes installed at Park Sheet Metal of Coventry has allowed the automotive sub contractor to break new ground in the production of the new Lea Francis 20/230 sports roadster Normally progressing a modern car design from concept to production is a fearsomely expensive business
This article was originally published on Manufacturingtalk on 25 Jun 2001 at 8.00am (UK)
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Expanding the advantages of its modular concept design, two new versions of the LVD Axel 'flying optics' laser profiling machine are now available with fully integrated shuttle tables
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A flexible manufacturing system for sheet metal components is able to offer integrated component production involving a turret punch press, laser profiling and right angle shearing.
However, at Park Sheet Metal the adoption of the pioneering methods means both the sub-chassis tub and the front and rear suspension sub-frames are constructed directly from laser cut components, produced on LVD Impuls and LVD Helius laser profiling machines supplied by LVD (UK) of Marlow.
These parts are then formed on one of the company's LVD multi-axis PPEB press brake and glued, bolted, riveted or welded together.
The resulting structure combines the high torsional rigidity and light weight of a monocoque but retains/improves on the low-volume cost- effectiveness of a welded tube substructure.
Such is the process capability, that the structure is equally suitable for clothing in a moulded glass fibre or a pressed/hand-made metal body.
Equally, use of fabricated subframes, to support the suspension, has introduced considerable flexibility in development of the suspension geometry, allowing it to be finalised much later in the car's evolution.
The development work undertaken by Park Sheet Metal on the Lea Francis project exemplifies a portion of its capabilities.
As well as prototypes, the company is a key supplier of components, sub- assemblies and low volume bodyshell assemblies to a number of luxury car, light van, motor sport and heavy goods vehicle manufacturers.
In addition, it provides specialised sheet metal manufacturing services for a variety of other industry sectors.
The company has invested in a wide range of sophisticated computer-aided design and manufacturing facilities which support a highly skilled workforce of 150 or so people.
Notable milestones have included hand building the original Motor Show prototype of the Jaguar XK220, while thousands of people have travelled to their weddings, or made a final trip to meet their maker, in Park Sheet Metal-bodied Daimler Limousines.
Jonathan Payne, the director responsible for the company's fabrication shop, says: "We tend to say to customers that if they can draw it, then we can make it.
Our on-going investment in LVD-supplied equipment has helped us to substantiate that claim.
The first LVD machine was a press brake which, at the time, represented very good value for money.
In a way that machine was the key to the door as the service that we had received from Marlow was the deciding factor in favour of the Impuls flying optics laser profiler." The Impuls was Park Sheet Metal's second laser machine, as the company had appreciated the advantages of this type of equipment fairly early on.
A steady requirement for batches of 300 to 500 components, often with odd or curved shapes, made it a 'natural' laser user.
Materials regularly processed include mild steel, Zintec, aluminium, stainless steel and glass as well as wood, plastic, bronze and brass.
With its twin-pallet system and 3,000 mm by 2,000 mm bed, the Impuls made larger batch quantities easier to handle, while its 2 kW laser increased thickness capability to 12 mm in mild steel.
The machine was then followed by an LVD Shape Delta 1250 Long Beam punch press, to aid the processing of a lot of small holes in components.
This was followed by the hybrid Helius installed alongside the Impuls to replace the original laser machine.
The Helius has a 1,250 mm by 2,500 mm bed capacity and is fitted with the optional fourth-axis rotary indexing attachment.
Its more powerful 3 kW Fanuc laser allows Park Sheet Metal to cut steel up to 20 mm thickness and aluminium up to 8 mm thickness.
"We didn't have the space for a second Impuls," Jonathan Payne remarked, "but the smaller capacity of the Helius has led us to work in generally thicker material, while higher volumes go onto the Impuls.
We've been extremely pleased with the performance of both machines; each has a large Z-axis with combined height sensing so we can use them for rapid 'clipping' of parts produced on our power presses." He also describes how the 'Laser Eye' facility allows perfect alignment and datuming for laser cutting additional features on partially complete assemblies.
"For example, we can laser cut the rear door of a van by cutting out the lock, handle and rear window features on the laser after the inner and outer panels are assembled." Possession of these facilities and the expertise developed through in-house applications has also allowed Park Sheet Metal to diversify, with some success, into more general sheet metal work.
Because the company is well used to satisfying a very demanding client base, and has the necessary quality systems in place, it has been able to adapt its methods with reasonable ease.
A prime example is in assisting press work specialists with development of the blank shape needed to work with existing drawn tooling, which expedites development of the blanking tools.
"A considerable amount of the work we produce as a subcontractor is, in fact, quite similar to tasks that we have undertaken on our own behalf," says Jonathan Payne.
"That allows us to offer third parties a well- organised, efficient service.
Had we not already invested in laser machines for our own use, then that option would not have been available to us," he says.
He also explains that the pioneering work on the development of the Lea Francis tub would not have been possible.
From the start, the structure was engineered for laser and punching machine based fabrication, while the body pattern was made using laser cut wooden profiles that slotted together, egg-crate fashion.
These were then coated and filled to produce the back.
"A further refinement is that the sub-structure is self-jigging.
This means provided the defined assembly sequence is followed, it goes together like a Meccano model without need for complicated alignment/assembly tooling," he says.
"Here the tub structure takes full advantage of the consistency, repeatability and accuracy of the LVD laser machines and punch so that it assembles as a kit of parts." To which he concluded: "When the vehicle reaches production, we will be able to take full advantage of the facilities that we have available.
For instance, although the lasers can easily cut holes of 3 mm diameter, it may well prove to be more productive, in batch manufacture, to use the punch press to make all the holes, then align the sheet on the laser using the 'Laser Eye' for profiling.
It's a very useful and flexible set of production process options to have in hand," he says.
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