CUSTOM FABRICATION

 

Occasionally, we do custom fabrication for people outside of our usual customer base. Here we have a beautiful custom fabricated stainless steel countertop done for a local couple.


This countertop was fabricated to match the couple’s other stainless steel appliances. After several hours of programming and fitting samples, we started with 14 GA #4 Brush Finish Stainless Steel also called Directional or Satin Finish. Since its invention in 1913, stainless steel has been a multitasking wonder and is the most popular finish for appliances and matching countertops. It can make a sweeping design statement and makes clean up a breeze. Also, stainless steel (unlike other countertop metals) won’t patina. Brush finish is the most common of stainless steel cosmetic finishes and is characterized by fine polishing grit lines that are uniform and directional in appearance. For this project, the finish was produced by polishing the metal with a 120-grit Walter Hand Sander.

Cutting

Blanks were cut using our Whitney plasma cutting system with Hypotherm HPR260 torch with 80″ x 20′ cutting table capable of cutting up to 1-1/4″ thick steel.

Bending

Bending was performed on our Cincinnati Press Brake with Gladwin Crowning System and JMT Durmazlar AD-S Press Brake with 120” bending length.

Welding

Finally, the welding process used was Gas Tungsten Arc Welding (GTAW), also known asTungsten Inert Gas (TIG) welding. This is an arc process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-current weld power supply produces electrical energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma. TIG welding is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds.

http://www.hgtv.com/design/rooms/kitchens/metal-countertops-copper-zinc-and-stainless-steel

 

METABO CUTTING TOOL

CUTTING TOOL CLASSIFICATION

In the context of machining, a cutting tool (or cutter) is any tool that is used to remove material from the workpiece by means of shear deformation. Cutting may be accomplished by single-point or multipointtools. Single-point tools are used in turning, shaping, plaining and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip.

Cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. Also, the tool must have a specific geometry, with clearance angles designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on the workpiece surface. The angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and margin size. In order to have a long working life, all of the above must be optimized, plus the speeds and feeds at which the tool is run.

CUTTING TOOL TYPES

Linear tools include tool bits (single-point cutting tools) and broaches. Rotary tools include drill bits, countersinks and counterbores, taps and dies, milling cutters, reamers, and cold saw blades. Other tools, such as bandsaw blades, hacksaw blades, and fly cutters, combine aspects of linear and rotary motion.

Source: http://en.wikipedia.org/

CINCINNATI PRESS BRAKE

BENDING ON A CINCINNATI PRESS BRAKE

RATING

All CINCINNATI press brakes are rated for maximum bending pressure, or tonnage. Tonnage can then be converted into ending capacities through an understanding of basic factors affecting the formability of metal. Bending factors, or “rules of thumb,” for press brake forming are based on using mild steel (60,000 psi maximum tensile strength).

Vee Die Opening and Inside Radius

The recommended vee die opening for mild steel up to 1/2” (.500”) thick is eight times the metal thickness. For thicker than 1/2” mild steel, it may be necessary to increase the vee die opening up to ten times the material thickness to minimize cracking of the material. To determine the vee opening for a simple 90° bend, multiply the metal thickness by eight. The answer is then rounded to the next higher 1/8” figure. For example: 14ga. (.075”) x 8 = .600”. This is rounded to a 5/8” vee opening. The inside radius of a bend in mild steel is about 5/32” (.156”) x the vee die opening regardless of the gauge of metal being formed. This figure was determined by measuring formed samples bent over various die openings. To illustrate: If a 1/8” (.125”) sheet and a 1/4” (.250”) plate are formed over a 2” vee die, each will have the same inside radius of approximately 5/16” (.312”).

GENERAL SPECIFICATIONS OF THE 230CBII HYDRAULIC PRESS BRAKE

  • Capacity 230 Tons
  • Overall Length of Bed & Ram 14′
  • Distance Between Housings 12’6 3/4″
  • Stroke 10″
  • Open Height 17″
  • Closed Height 7″
  • Throat Clearance 8″
  • Speeds:
  • Approach 155″ per min
  • Form 8-16-35″ per min
  • Return 175″ per min
  • Back Gage Speeds X-Axis’, 1200″ per min
  • Main Motor Horsepower 15

EQUIPPED WITH:

  • Cincinnati Heavy Duty Back Gage
  • Electric Foot Switch
  • Pedestal Palm Button Station
  • Manuals
  • Interlocked Construction
  • Clevis Mounted Self Aligning Cylinders

APPROXIMATE OVERALL WEIGHT 33500 LBS

APPROXIMATE OVERALL DIMENSIONS 13’5″L X 60″W X 126 1/4″

 

Source:http://www.e-ci.com/

JMT PRESS BRAKE AQUISITION

JMT PRESS BRAKE OPERATION

Hydraulic press brakes offer accuracy and versatility for bending simple or complex metal parts. JMT press brakes have mulitple axes and come in a wide range of lengths and tonnages.

http://www.wellerusa.com/

 

JMT AD-S PRESS BRAKE BREAKDOWN

  • 120″ bending length
  • 150 US Tons
  • Y1, Y2 Ram Positioning
  • X/R CNC Back Gauge
  • Sliding Front Sheet Supports
  • Delem DA66W Control
  • CNC Crowning, WILA
  • WILA American Standard Hyd. Punch Clamping with Pump
  • Z1, Z2 Controlled Finger Movement
  • AKAS Laser Guarding

JMT AD-S PRESS BRAKE SAFETY

AKAS LASER GUARDING

The AKAS® Press Brake Laser Guarding safety system is the most sophisticated press brake point of operation safeguarding package on the planet. OEM or retrofit, this incredible technology allows operators to handle even the smallest parts safely – even right up next to the die – with no significant effect on production.

The laser – accident preventing light barrier AKAS® is an electro sensitive protective and controlling device
(ESPE) which has the function to protect operators from accidents.

This happens as follows: Before a part of the body is squeezed between two opposed moving machine parts,
this part of the body interrupts at least one light beam. By this means the movement of the machine is stopped,
before it comes to an injury.

AKAS®
– meets IEC 61496, Type 4
– is self- monitoring without additionally wiring.
– easy to adjust after tool changing.

Sources: http://www.pressbrakesafety.com/

& Fiessler Elektronik

TIG WELDING IN METAL FABRICATION

TIG Weld

PROCESS

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-current weld power supply produces electrical energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma.

GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding, uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.

For more information about TIG Welding go to:

http://en.wikipedia.org/wiki/Gas_tungsten_arc_welding

METAL: AN EXCELLENT CONDUCTOR

THE PHENOMENON

Have you ever walked through your house and touched a piece of wood, then touched a metal pipe or doorknob? Why does the metal feel colder if they are both the same temperature? This phenomenon is known as Heat Conduction and is a simple property of physics. Wood is a poor conductor of heat. Metal, on the other hand, is an excellent conductor of heat and quickly draws heat away from your skin and gives you the impression that it is cooler than it actually is. This also explains how you can put your hand in a hot oven and not be burned by the air inside, but you will feel extreme pain should you touch a metal cake pan at the same temperature as air is a much poorer conductor of heat than metal.

EXAMPLES

Other Examples of Heat Conduction

Heat conduction, also known as thermal conduction, is the process where heat is transferred within a body due to the collision of neighboring particles.

Everyday Heat Conduction
Here are some examples of the process of heat conduction:

  • A cold cast iron skillet is placed onto a stovetop. When the stove is turned on, the skillet becomes very hot due to the conduction of heat from the burner to the skillet. You decide to touch the handle of the skillet after it has been on for several minutes, and now the handle is hot, too. This is because heat was conducted through the portion of the skillet in contact with the stovetop all throughout the rest of the skillet.
  • A shirt is placed on an ironing board to be ironed. Heat from the iron is conducted to the shirt, making it easy to iron out all those unsightly wrinkles and make the shirt look sharp.
  • The engine of a car is turned on, and the hood becomes warm due to the conduction of heat from the engine to the hood of the car.
  • A cube of ice is placed into the hand of a man. Over time, heat conducted from the man’s hand to the ice cube will cause the ice to melt.
  • An individual builds a fire, and then moves around the burning logs with a poker. Heat is conducted from the burning logs to the poker, making the end of the poker become red-hot if it is left in the fire too long.
  • When a young girl walks outside barefoot on a hot summer day, the heat from the asphalt is conducted to her feet, and her feet become hot. This is because heat is conducted from the asphalt to the girl.
  • A boy grabs a penny from his tabletop, and it feels very cold to the touch. After holding it for a few seconds, the heat from his hand is conducted to the metal coin.
  • The radiator is turned on to warm a house during a cold day, and the owner of the house puts his hat on top of it. The hat becomes warmer due to the radiator conducting heat to it.
  • A boy places a hot dog onto the end of an unraveled metal clothes hanger and begins to cook it over the fire. After a time, the hanger begins to feel hot due to the heat conducted from the hot fire all along the piece of wire.
  • When a piece of hot lasagna is placed onto a porcelain plate, the plate will feel warm to the touch after several minutes due to the conduction of heat from the just-cooked food to the plate on which it sits.
  • A young boy comes inside after playing on a snowy day, and huddles up to his mother to become warm. This is because heat is transferred from his mother’s body to his own through the process of conduction.

STAINLESS STEEL-WHY’S IT CALLED THAT?

Stainless Steel Drop DoorBritish metallurgist Harry Brearley developed stainless steel in 1913 searching for a better lining for cannons.  He discovered that chromium had the ability to create an oxide lining, and that steel made from iron and chromium resisted many corrosive chemicals.

Stainless steel coating is a thin, transparent film of iron oxide and chromium.  This prevents soap, food, water, and air from getting to the metal below and eating it away.  Stainless steel is very sanitary since its coating is so smooth.  Bacteria, fungi, and dirt have nowhere to hide and are easily washed away.  For this reason, commercial kitchen surfaces and cooking equipment are often made of stainless steel.

Stainless steel can “heal” itself!  If scratched or nicked, the protective oxide immediately recoats the damaged area.  Because of its great ability to resist rusting , it is an ideal material for cutlery, pots and pans.

Stainless steel differs from carbon steel by the amount of chromium present. Unprotected carbon steel rusts readily when exposed to air and moisture. This iron oxide film (the rust) is active and accelerates corrosion by forming more iron oxide; and, because of the greater volume of the iron oxide, this tends to flake and fall away.

Stainless steels contain sufficient chromium to form a passive film of chromium oxide, which prevents further surface corrosion by blocking oxygen diffusion to the steel surface and blocks corrosion from spreading into the metal’s internal structure, and, due to the similar size of the steel and oxide ions, they bond very strongly and remain attached to the surface.

Stainless steel’s resistance to corrosion and staining, low maintenance and familiar lustre make it an ideal material for many applications. There are over 150 grades of stainless steel, of which fifteen are most commonly used. The alloy is milled into coils, sheets, plates, bars, wire, and tubing to be used in cookware, cutlery, household hardware, surgical instruments, major appliances, industrial equipment (for example, in sugar refineries) and as an automotive and aerospace structural alloy and construction material in large buildings. Storage tanks and tankers used to transport orange juice and other food are often made of stainless steel, because of its corrosion resistance. This also influences its use in commercial kitchens and food processing plants, as it can be steam-cleaned and sterilized and does not need paint or other surface finishes.

Stainless steel is used for jewelry and watches with 316L being the type commonly used for such applications. It can be re-finished by any jeweler and will not oxidize or turn black.

Some firearms incorporate stainless steel components as an alternative to blued or parkerized steel. Some handgun models, such as the Smith & Wesson Model 60 and the Colt M1911 pistol, can be made entirely from stainless steel. This gives a high-luster finish similar in appearance to nickel plating. Unlike plating, the finish is not subject to flaking, peeling, wear-off from rubbing (as when repeatedly removed from a holster), or rust when scratched.

Some automotive manufacturers use stainless steel as decorative highlights in their vehicles.

BASS CREEK GOLF SCRAMBLE – SATURDAY JULY 11, 2015

On July 11, 2015 Bass Creek Golf Club will be hosting a 9-Hole Golf Scramble to raise money to maintain the Orfordville Public Library.  The scramble will begin with a 1 PM shotgun start.  There will be auction items, hole prizes, and a variety of raffles, games and activities available throughout the day.  Dinner will be served at 5 PM.  Please join Akey Manufacturing in supporting this family fun event!