FEATURE ON SAWING

Smart automation: Sawing and stacking tubes

Neumeister Hydraulik has modernised its sawing centre and now relies on a fully automatic system from Behringer. Thanks to the new system, cylindrical tubes can now be sawn fully automatically with sections stacked automatically in pallet cages – an important step towards efficiency and future-proofing.

Neumeister Hydraulik was founded in 1929 by Otto Neumeister in Neuenstadt am Kocher, where it today employs around 300 people. The company specialises in the development and manufacture of hydraulic cylinders for lifting heavy loads. It produces around 100,000 hydraulic cylinders per year for a wide range of applications. For cylinder production, mainly round tubes with outer diameters of 50 to 250 mm are sawn. The tube sections usually have a length of 1 to 1.2 m. In addition, many short sections with a length of around 20 mm are required for the production of flanges.

Neumeister opted for a modern chain magazine that enables entire bundles to be efficiently loaded and easily separated, reducing crane movements and simplifying operation. In addition, the magazine has a remnant storage system to divert long remnants back to the infeed side and store them again. The entire material handling process is fully automated.

At the heart of the new sawing centre is the Behringer HBM440A-PC-E bandsaw with a cutting range of 440 mm. Thanks to the PC control system, it is designed for fully automatic operation and is easy to use. The SpeedCutting technology of the HBM440A, in combination with dynamic process control for pipes,  increases system throughput. The machine continuously adjusts the saw feed to the material cross-section and thus ensures optimum utilisation of the tool.

More information www.behringer.net

Avent Extrusion Steels opts for Gentiger saws

Avent Extrusion Steels & AVA Special Steels has invested in two new high-performance Gentiger bandsaws supplied by Prosaw. James Avent, director at Avent Extrusion Steels, says: “We can confidently say it’s the best investment we’ve ever made in our sawing capacity.”

Avent has used bandsaws for nearly 25 years since its inception, and the company has seen a wide range of machines come and go.

“The Gentigers have truly raised the bar,” sates Avent. “These saws have increased our cutting capacity by almost 20% in terms of size and, when paired with carbide-tipped blades, they cut up to five times faster than the machines they replaced.”

He continues: “This exceptional performance has enabled us to reduce our bandsaw count from seven machines down to five, without compromising output – in fact, quite the opposite. The Gentigers easily handle the workload of the previous four saws they replaced and still have more to give. Such a reduction not only streamlines our operations but also leads to significant energy savings, a vital factor given today’s energy costs and the growing emphasis on sustainability.”

Another stand-out attribute of the saws is their ability to cut tough materials while still delivering smooth surface finish and extremely flat cuts.

“We’re now able to saw material down to near-net sizes, which means less secondary machining and reduced waste. Combined with their ability to achieve remnant lengths as small as 7 mm, these bandsaws have brought a massive improvement to our material efficiency.”

In addition, the Gentigers feature energy monitoring capabilities, allowing Avent to track and record electricity consumption.

More information www.prosaw.co.uk

Stockholder upgrades bar storage system

German steel and aluminium stockholder Günther+Schramm has upgraded its high-bay store to ensure the continued reliability of the Königsbronn materials stocking and distribution operation. Carried out by engineers from the original warehouse manufacturer, Kasto Maschinenbau, the modernisation service is available to customers in the UK and Ireland through the group’s subsidiary in Leicestershire.

Supplying over 60,000 tonnes of metals and plastics annually to manufacturers in southern Germany and neighbouring countries, Günther+Schramm employs 180 people who place a lot of emphasis on timely delivery of the high quality products. This activity requires a smoothly functioning warehouse, but the company’s pre-existing storage and retrieval system had started to impose limitations on what was possible.

Michael Sticke, assistant operations manager responsible for the Kasto system in Königsbronn, says: “After three decades of service, the original mechanics were causing frequent disruptions, leading to significant downtime. It was a classic example of a bathtub curve, where initial issues subside, followed by a long, stable period before a rise in failures due to age and wear. We were always at risk of waiting a week or two for a replacement component, preventing us from serving our customers in the meantime.”

So the decision was taken to modernise the Kasto SNLS 5000/7100 S high-bay bar storage system, whose cassettes accommodate material up to 7.1 m in length to a maximum weight of 5 T per location. Given the stockholder’s positive experience with Kasto equipment over the years, including various sawing systems such as a KASTOvariospeed C 15 circular saw with robotic handling of cut pieces, Günther+Schramm naturally chose the same firm for the extensive retrofit.

More information www.kasto.com

Software opens saw blade opportunities

The Loroch range of circular saw-blade grinding machines from Vollmer has seen a software update to the Twin 860 machine, a ‘2-in-1’ solution for grinding metal saw blades with CBN abrasive and TCT blades for the metal-cutting and wood industries. The new software can be integrated into new and existing machines to create new business opportunities for manufacturers.

Users of the Loroch Twin 860 can purchase four different software packages. The software program for ‘skip-tooth’ processing on circular knives and saw blades opens many new business opportunities for Vollmer customers. Perfect for generating a randomly arranged sequence of teeth and gaps, it is even possible to process saw blades with pointed and curved teeth. Skip-tooth blades are versatile enough for everything from wood and plastic to bone and Corian,  meaning manufacturers can now grind and re-grind skip-teeth saw blades for use in the food, medical and FMCG industries.

The plunge grinding program is another software introduction that can benefit the food industry supply chain. Developed for processing circular knives with any number of plunges, the shape of the grinding wheel is reproduced in every case. The number of teeth can either be distributed evenly around the circumference or ground one after the other on a limited segment. Users can even create micro-tooth wave profiles by entering different plunge depths for successive teeth. Manufacturers can now apply V-pointed grinding wheels or wheels with EDM-generated profiles to reduce production times.

Loroch experts have also created a software program for circular knives to accommodate single or double-sided grinding. The software combines with the kinematics of the Loroch Twin 860 machine to permit a maximum bevel angle of 75° at the front and 60° from the back.

More information www.vollmer-group.com

How to choose an iron-cutting machine

Iron-cutting machines are indispensable machinery in sectors such as the mechanical and metalworking sectors, where precise and rapid cutting of ferrous materials is essential. Sthemma, owner of the Thomas range of bandsaws, sets out the different types of iron-cutting machines, the advantages of professional versions, and provides guidance on how to choose the best model.

Manual iron cutters are among the simplest solutions, used mostly for small jobs or occasional operations. Although powered by hand, these machines guarantee good precision and are suitable for cutting thin thicknesses.

Toothed disc cutters for iron are the preferred choice for those seeking high performance and precise cuts on hard materials. The toothed disc is designed to withstand intensive cuts and ensures a long tool life. These models are particularly suitable for precision work on thick and hard materials, such as iron pipes and bars. They also offer a higher cutting speed.

Bandsaws for iron are best suited to continuous, repetitive cuts. Unlike disc saws, they use a band blade that provides greater flexibility and precision, especially on long, irregularly shaped materials. The band blade also provides burr-free cuts.

Professional iron-cutting machines stand out for a series of advantages that make them indispensable in the metalworking sector. In addition to power and precision, Sthemma says that a professional mitre saw guarantees maximum safety and reliability. They also offer speed and efficiency without compromising quality of cut.

Factors for selecting the best mitre saw for iron include engine power, blade or disc type, cutting capacity, and maintenance requirements.

In conclusion, professional cutting machines offer significant advantages in terms of precision, speed and versatility, making them an indispensable tool in the metalworking sector.

More information www.sthemma.com