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CNC bending and foldingcnc punchengineeringEngineering and Sheet Metal Newslaser cuttingsheet metalSheet metal dataSheet metal fabricationsSheet metal facilitiesTrumpf manufacturing equipmentUncategorizedWelding

We are bananas about our CNC punch press tooling at V and F Sheet Metal!

Monday, March 5th, 2018

CNC punch press tooling

The latest component I’ve been asked to make has given me the opportunity to talk about CNC punch press tooling, and more specifically the banana tool. Although the part is simply circular in shape, it still needs some thought on how this shape is created. We could have used the Trumpf fibre laser but in this case we chose to run the job on the Trumpf 3000. If this machine had been busy then we could have swapped to the Trumpf 200. Obviously, we like to offer this flexibility in our work shop and our regular customers appreciate this, as they know their job will not be held up in a queue.

Banana tooling used to CNC punch a circular component

Radan view of component

The first photo is a Radan view of the part. Below the circular part is the CNC punch press tool used to produce it, a banana tool. This tool has a choice of external and internal radii. These could be same or different to each other. In this case the internal radius of the tool was used to produce the external circumference of the component. We have many tools available at V and F Sheet Metal so if one doesn’t suit, we’ll probably find one that will! The tool could be used to create the external radius of the part or the internal radius of a hole in a piece of metal.

Radan nest of parts

Radan nest of parts

The second image shows the Radan nest of parts arranged on a 2m x 1m sheet of 3mm thick aluminium.
Obviously as components are cut out of the sheet they will fall out so there is a chute underneath the machine for collection. All holes in the component are punched out first and the cutting out of each individual component is the last step. The left over “skeleton” sheet and punched slugs are recycled. For the final stage of production the components are sent off for powder coating.

Close up of component produced using a CNC punch press banana tool

Close up of component produced using a CNC punch press banana tool

Please feel free to contact us at V and F Sheet Metal if you would like to talk about CNC punch press tooling. We’re always happy to help. Call us on 01489 577786 or email salea@vandf.co.uk.

Laser cutting an intricate decorative handrail in Hampshire 2018

Tuesday, February 13th, 2018

Laser cut handrail

laser cutting Radan image

Radan image

laser cutting Cut out handrail

Cut out handrail

Laser cutting Close up of pattern

Close up of pattern

Laser cutting sheet metal work is a process we’re proud to offer at V and F Sheet Metal. So I jumped at the chance to talk about a recent interesting job that came our way. My customer required a rather intricate decorative handrail made in stainless steel for installation in a lady’s home. The complex and artistic pattern makes it an ideal job for our Trumpf 3030 3KW fiber laser.

We received a DXF file from our customer. A file with the .DXF file extension is a Drawing Exchange Format file developed as a type of universal format for storing CAD models. DXF files can easily be opened in CAD packages enabling an accurate and competitively priced quote to be created. The red photo is the image created in Radan software.

The remaining photos show the cut out rail covered in a plastic coating. This coating is removed after laser cutting.

Do you have a complex project you’re looking at right now? If you think laser cutting may be the way forward then we may be able to assist you! Please give our friendly team a call on 01489 577786. Alternatively email us on sales@vandf.co.uk.

Cluster tool and CNC punching sheet metal components

Tuesday, February 13th, 2018

In this post I thought I would concentrate on a recent project which makes use of a cluster tool. A customer from overseas required a 1U chassis made from 1.2mm mild steel to slot in to a 19 inch rack. If you are not familiar with the U, it is a unit of distance used to measure height of standard racks in which computer, video or audio components are mounted.

Over a thousand sets of components were required and as you can see from the photos, each part contains many ventilation slots. Due to the high volume of parts needed, I suggested to the customer that we use a punch press cluster tool to produce the slots, thus cutting down on production time and saving money. In fact the tool paid for itself within the first batch!

The blue images are produced using Radan software. The NEST image shows each set of components laid out on a sheet of 2m x 1m mild steel ready to be punched out on the Trumpf 3000R. If the Trumpf 3000R had been in use it would a have been equally possible to use our Trumpf 200R for production. We are a flexible bunch here at V and F Sheet Metal!

If this has given you an idea about the possible uses of tooling on a product you are looking to have made yourself then please contact us. We may be able to save on your production time and cut down on the final cost. We are a friendly team at V and F Sheet Metal and one of our experienced engineers is always happy to discuss all your requirements with you.
Call us today on 01489 577786 or email at sales@vandf.co.uk.

Radan image of ventilation slots

Radan image of ventilation slots

NEST image of cluster tool

NEST image

Close up of NEST image

Close up of NEST image

Punched component

Punched component

Chassis in production

Chassis in production

Roll up, roll up! Step this way for Sheet Metal production January, 2018

Thursday, February 1st, 2018

Formed sheet metal circular component

Now this sheet metal product caught my eye whilst walking around the factory this week. I thought it was worth a mention as it combines two separate processes of sheet metal manufacturing, namely bending and rolling. On both images, on the inside of the rolled end it’s possible to see a series of lines. This gives a clue to the process used, as a series of bends were made using the Trumpf 7036 to begin to produce a preform curve.

As the lines disappear and the inner surface appears smooth, this indicates that the metal has been rolled on a set of rollers. At V and F Sheet Metal we have a series of hand rollers and brand new powered rollers. We have the capability to roll up to 1m wide and 3mm thick mild steel. However, we are able to roll up thicker metal in smaller strips when the need arises. Please take a look at our plant list on rolling sheet metal work for more detailed information and examples of past sheet metal projects.

These particular items were used to clamp small exterior floodlights to poles around a university campus. They were made from 2mm mild steel and then they were powder coated.

For more examples of rolled sheet metal work please also take a look at our Rolled Sheet Metal Work Pinterest Board

If you have a product that requires rolling or forming as part of your design then please don’t hesitate to give us a call on 01489 577786 or email if you prefer at sales@vandf.co.uk. We can read DXF, DWG, SAT and STEP CAD files and produce drawings where needed from our customers sketches or samples. Our friendly sheet metal engineering team are always happy to help and love a challenge. With over 50 years experience between them there’s not much they haven’t come across.

Formed circular sheet metal component

Formed circular metal component

Metal circular component

Metal circular component

Manufacturing Metal Enclosures using Radan software, Great Britain 2018

Sunday, January 21st, 2018

Sheet metal Enclosures

Today we’re looking at the production of metal enclosures. I think this process displays nicely the flexibility and time saving features of Radan software. So how do we begin the process? Well in this case the customer required production of a sheet metal enclosure using 1.2mm aluminium alloy. We always start with a 3D model on Radan, this allows us to make sure all the fixing holes line up before starting production. This model may come directly from our customer as a STEP or SAT file. If that is not available to us we will create the 3D model using our customers dimensioned drawings. Either way we have control of the basic design information needed to produce the correct developed blank shape and size.

3 D Radan model

3 D Radan model

Developed blank in flat

The developed blank shows the shape of the final enclosure in the flat (grey). The dark blue surrounding the blank is the shape produced by all the CNC punch press tooling. The tooling can be added to the blank shape automatically by the software. We still have the ability to alter this tooling to suit our own requirements where needed. Following on from this the blanks are set out on a full sheet of metal. In this case the sheet size is 2M x 1M. When CNC punching our Trumpf CNC punch presses can work with sheet up to 2.5M x 1.25M. Smaller panels can be programmed where needed for small components or smaller batches of work. This is definitely where the versatility of the Trumpf machine comes in to it’s own.

You might have noticed that the back 2 components have been turned at 90 degrees to the rest. Why so ? This is the region where the clamps hold the metal in place. Therefore the turning of these components is necessary but still allows for the maximum number of parts to be punched from one sheet. In addition, we have the capacity to to produce these parts on either the Trumpf 200 or 3000 as the same tooling fits both machines. A useful feature in a busy workshop, allowing production to be swapped from one machine to another.

Nest of parts

Nest of parts

Metal Enclosures

Metal Enclosures

Finally, once all of the sheet metal enclosure components have been CNC punched, we deburr the edges before moving on to the last stage which is folding. The image here shows a skilled employee folding up the components on one of our Trumpf 7036 CNC press brakes. By using the Radan software at the design stage, the final components should perfectly match the model. This allows us to save time and effort when making the first batch of samples or production. Any alterations can be fed back to the 3D model and subsequent 2D tooled CNC punching nests. This process can also be applied when a customer requires a design change to take place.

Folding up of components

Folding up of components

Finished component

Finished component

Please feel free to look at our website pages which gives up to date information on our plant list, tooling and design data. You have the ability to search all our blog posts so if this post doesn’t quite fit your needs then something else will! There is also an extensive gallery of photos.

If after reading this you think we could help you then please contact our engineering team at V and F Sheet Metal on 01489 577786 or drop us an email at sale@vandf.co.uk. We can’t wait to hear from you!

Manufacturing a Sheet Metal Stainless Steel Guide Plate with tapped holes

Tuesday, January 9th, 2018

Stainless Steel Guide Plate

Recently at V and F Sheet Metal we were asked to make a guide plate with tapped holes and I thought this would make an interesting topic for discussion. As with any project the initial phase of manufacturing starts with a clear and concise drawing. This should provide exact dimensions and if required precise position of holes and slots. With this particular design I was able to program the part within 10 minutes using Radan software. This batch of 50 guide plates were then manufactured from 2.5mm thick 304 stainless on the Trumpf 3000 machine.

A couple of the photos here show the sheet on the punching machine and illustrate a number of useful points which may not always be obvious to the customer. Firstly if you look carefully at the image of the CNC punching the guide plate, it is possible to see that at the back of the machine I turned the last two rows of plates to achieve the maximum number of components from the sheet. The nest diagram reveals this clearly and shows the small amount of waste material that will be left at the end of production. Secondly, although not obvious from the photos, this job actually made use of an off cut of material from a previous job, again allowing me to reduce the cost to the customer. In addition there was no need for special tooling as we have an extensive tool library at V and F Sheet Metal. Another money saving feature.

Finally I thought it was worth drawing your attention to the tapped holes on these guide plates. The Trumpf 3000 is equipped with a number of tapping tools and an M4 tap was used on these guide plates to produce a strong, clean thread within the material. It is an efficient process and cheaper than the traditional tapped cutting of threads which produces swarf, which must then be removed from the underneath the machine.

Hopefully you have found this useful and if you think V and F Sheet Metal can help you then please give us a call on 01489 577786 or email today at sales@vandf.co.uk. We look forward to hearing from you!

Stainless steel Guide plate

Stainless steel Guide plate

Stainless steel Guide plate program

Stainless steel Guide plate program

TAPPING EXPLODED TOOL

TAPPING EXPLODED TOOL

TAPPING CROSS SECTION

TAPPING CROSS SECTION

CNC punching the guide plate

CNC punching the guide plate

CNC punched nest of guide plates

CNC punched nest of guide plates

We love making folded Sheet metal boxes!

Sunday, January 7th, 2018

Folded sheet metal boxes

Folded sheet metal boxes

Folded Sheet Metal Boxes

Are you looking to produce a folded sheet metal box? Then look no further as we are here to help you! Over the years we have produced a huge number of boxes ranging from the small and simple to large and complex. We use high tech equipment which allows us to CNC punch sheet metal from 0.4mm up to 5.0mm gauge in a range of steel, aluminium and stainless steel alloys. Furthermore if you require thicker gauges this is no problem as we employ the services of our Trumpf 3030 3KW fiber laser cutting machine.

I’ve include this image as it’s a typical example of the type of folded sheet metal box we are asked to make on a daily basis. First of all nearly all of our sheet metal projects start their life as a 3D model using Radan sheet metal development software. Once checked and approved, the model is used to produce a flat pattern ready for use on one of our CNC punching machines. After punching, the edges are deburred and the panel folded up in to the final shape using one of our many CNC press brake bending machines.

This may be the final product especially if the box is going to be placed “out of sight”. However, more often than not our customers require their boxes to be treated or finished. For example we can powder coat, zinc plate or anodise components to produce a perfect cosmetic finish.

If you would like to learn more about the various stages of metal box design and production then please go to our web page on Box Fabrication. Finally if you need any more help with your project then we’re always happy to hear from you at V and F Sheet Metal. Please just call on 01489 577786 or drop us an email at sales@vandf.co.uk.

Please feel free to look on our website for more general information on CNC bending and CNC press brakes.

Z angle aluminium brackets laser cut and folded in Great Britain 2018

Wednesday, January 3rd, 2018

Laser cut aluminium strips

Laser cut aluminium strips

Z Angle Brackets

If you require aluminium brackets but you’re not sure who to contact then look no further! Here at V and F Sheet Metal, Hampshire we have the facility to help you. We have many years of experience to ease your journey from the initial idea or drawing through to final production.

Folding aluminium Z brackets

Folding aluminium Z brackets

First of all we begin the process using Radan 3D modelling design software before moving on to laser cutting and finally folding up to produce brackets.

The photos here follow the production of a simple aluminium bracket. Initially we cut out flat metal strip ready to be bent in to a z shape. Cutting out is quick using the latest technology Trumpf 3030 3 KW fibre laser. The second photo shows an individual strip in the process of bending using one of our Trumpf 7036 CNC press brakes. Finally once completed and inspected, the strips are packed up ready for delivery to the customer. If you would like to know more about bending then please read the CNC bending information on our website.

Folded aluminium Z angles brackets

Folded aluminium Z angles brackets

So please do not hesitate to contact us here at V and F Sheet Metal by calling 01489 577786 or emailing us at sales@vandf.co.uk. We have the ability to make many types of brackets and the expertise to assist you with your product from the initial idea through to design and final production. We look forward to hearing from you.

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