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Product category: CNC laser cutting and profiling machines
News Release from: LVD (UK) | Subject: Axel 2513S laser processing machine
Edited by the Manufacturingtalk Editorial Team on 21 May 2002

Laser boosts sheet metal manufacturing
output

In just 10 months following the installation of a laser processing machine equipped with shuttle table, a UK subcontractor has seen sheet metal output increase by over 40%.

In just 10 months following the installation of an LVD Axel 2513S laser processing machine equipped with shuttle table, Shearline Precision Engineering of Ely, Cambridgeshire, has seen output from its sheet metal manufacturing plant increase by over 40% This massive increase has been achieved principally from the Axel's greater productivity but also from its flexibility that has allowed Shearline to operate a more efficient Kanban method of working and significantly reduce work in progress

Formed in 1973, Shearline offers a true customer orientated total manufacturing solution which is capable of handling every process, from design through machining, sheet metalwork, painting and silk screen printing, assembly and delivery.

All these processes and operations are carried out in-house at the modern custom-built premises close to Ely.

Here, investment in state-of-the-art plant and machinery is bringing substantial benefits to customers drawn from ink-jet printing, oil and petrochemicals, scientific and medical, instrumentation, telecommunications, biotechnology and automotive industry sectors.

The Axel machine, supplied by LVD (UK) of Marlow, uses a GE-Fanuc 2kW axial fast flow (carbon dioxide) laser and is typical of the highly productive equipment in which Shearline invests.

It is housed in the fabrication cell alongside another LVD machine, a Delta 1000 turret punch press which has been recently refurbished and upgraded by LVD.

The fabrication cell is one of six that make up Shearline's sheetmetal manufacturing facility, which was originally set up in 1984.

Components produced in the cell range from small washers and brackets through to sheetmetal enclosures for ink jet printers, scientific instruments, CCTV camera chassis and other industrial electronics.

Shapes and sizes vary widely but the processed material is predominantly stainless steel with only between 10 and 20 per cent being either mild steel or aluminium.

Shearline already had a laser profiler but it wanted to increase capacity and reduce costs while continuing to improve quality.

Hence its purchase of the Axel machine with a twin-shuttle, table-based loading system.

Following installation, productivity was immediately boosted as material up to 1250mm by 2500mm in size can be loaded while the machine continues its programmed cutting cycle.

Higher productivity is also achieved by loading the machine table and the shuttle table at shift-end and then running 'lights out'.

This 'double table' worth of unmanned operation is achieved using the Axel's auto shut-down feature, which allows the machine to safely shut-down if there is a problem or when the work is completed.

Even at the start of a shift, time is saved by using the Auto Start-up feature.

This gives almost immediate availability of the machine at the start of the day as the operator only has to reference the laser head.

Although this takes between two and three minutes, it represents a 20-30 minute saving in productive time compared to the older machine.

In addition, the Axel machine is able to cut material up to 30% faster than the older machine due to the higher powered 2 kW laser as compared to 1.5kW.

Maximum cutting efficiency is also maintained due to the flying optics design where only the cutting head moves at up to 170m/min and the material is static on the table.

This enables the high processing speed to be achieved irrespective of sheet weight or size and the integrated beam length compensation system ensures the programmed trajectories are followed with maximum laser cutting efficiency across the whole working area.

Said David Kember, sheet factory manager: "The Axel has dramatically increased our output of laser cut material while the number of manned hours has been reduced.

We had to operate our previous laser machine over 24 hours to meet demand.

Now, we only need to man the Axel for two shifts but are getting more 'cutting hours' because of its efficiency.

Although only manned for 17 hours each day, it is cutting on average between 18 and 19 hours compared to the old machine where we would be lucky to get 15 hours of cutting even though it was manned for 24." But, in his view, the biggest boost to the overall efficiency of the whole sheet metal operation has come from the Axel's flexibility.

Set-up times are minimal and the machine is networked, not DNC linked, to Shearline's CAD PC.

This means programs are available on a virtual instantaneous basis, and the Windows compatibility of the GE-Fanuc control makes it easy to initiate the start of the profiling operation.

Paul Bird, Sheet Fabrication Cell leader, added: "All you have to do is key-in the material code and bring up the technology file which gives you the appropriate lens and nozzle that is required.

It then specifies the speed and power for both straight line and corner cutting.

Immediately you press the start button, away it goes." He then describes a recent 3mm stainless component which was cut in a straight line at maximum speed with power only reduced to negotiate the corners.

"This is all carried out automatically," he said.

As Kember maintained: "We can be cutting a part on the machine within five minutes of receiving the CAD drawing in DXF format from the customer.

It's as quick as that!" And he follows on to describe another aspect of the machine's flexibility and size capacity.

"We can load several different sizes of sheet for follow-on processing as long as the material and cutting data are compatible," he says.

This flexibility to cut sets of parts and not batches is a significant benefit, as Kember explained: "We can now cut parts to meet demand from assembly and not batch and store for build.

This has allowed us to improve production flow, with parts and materials drawn through the factory in a Kanban system.

You would not believe how this has reduced work-in-progress and increased our throughput," he maintains.

Like all sections at Shearline, the fabrication cell and the sheet factory keep strict production records.

This reveals that 10 months following installation, output of the fabrication cell has gone up by almost 30% and that of the sheet factory by well over 40%.

As Kember observed: "This is not all due to the Axel machine, as we have also improved our method of working, but it has certainly played a significant part," he insists.

Another requirement of the new laser machine was an ability to cut thicker materials.

The old machine struggled to cut 3mm stainless steel but the Axel is immediately able to cut 5mm stainless or more.

Before, if 5mm gauge came up, Shearline had to cut it using oxygen which was a slow process with a lot more time having to be dedicated to clean up and improve the finish of the components.

It can also cut aluminium, which like other highly reflective materials, is difficult.

The old machine simply could not cut aluminium and any need for this material had to be met by punching or milling, both more expensive options.

With the Axel's Back Reflection Control, aluminium does not present any problems.

In Kember's view an important contributor to the Axel machine's quality of cut is the capacitive height sensor built into the cutting head.

This maintains a constant distance between head and material, accommodating any undulations in the sheet.

And as Bird advised: "It is an excellent feature, easy to set-up and ensures the material surface is accurately followed." He describes how they increase the height setting when piercing in order to protect the nozzle from splatter.

"For example, on 3mm stainless we will specify a 1.5mm stand-off during piercing but revert to 1mm for cutting.

This reduces nozzle wear, which will last at least two weeks or more on the Axel compared to only two days on the old machine.

The LVD nozzles also cost less," he maintained.

Contributing to the overall efficiency of its laser sheet cutting and typical of the forward thinking to back the investment, Shearline also installed a tank facility for storing liquid nitrogen.

Previously, the gas was stored in a bank of bottles, which only lasted for around eight hours and production had to be shut-down while the bottles were changed.

Not only does the tank supply last longer and only need refilling once a month, it provides a continuous supply and the laser machine can continue working even when the tanker calls.

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