Sheet metal production of the future

Navigation for sheet metal processing
"Soon it will be inconceivable for most operations not to have such a system," said Dr. Mathias Kammüller, Managing Director of TRUMPF's Machine Tool and Power Tool Business Division. "It saves time, streamlines the process and greatly increases transparency." Through a computer monitor the operator can see the production orders and their status in the production process.
TruTops Fab is monitoring and controlling all of the processes from the initial sales quote up to the shipping papers. It provides a complete overview, from the calculations, through production and inventory, all the way up to billing. And the modular design allows users to adapt the software to their own requirements.

Dr. Mathias Kammüller, Managing Director, TRUMPF's Machine Tool and Power Tool Business Division

Punching and saving
Improved material efficiency is best exemplified by the new TruPunch 3000. In these punching machines, part geometries are configured on the sheet metal right up to the edge and are punched out in one punching stroke, without leaving behind an L-shaped sheet skeleton as had previously been the case. This increases the output of parts by an average of more than 10 percent. The machine works across the sheet row by row, punching alternately good parts and waste. A divider below the parts chute separates them. If necessary, the single punching head is capable of turning the parts and dropping them safely through the parts chute. "In this way, the sheet is completely cut up, so that in the end there's really nothing left," said Kammüller. "This machining strategy provides the largest potential cost-saving from punching, as the material accounts for almost three quarters of the parts costs."

New processing strategy
The work sequences for modern punching machines are highly sophisticated nowadays: fast, process-dependable and often automated. But there are a few exceptions. The sheet skeleton, for example, is a risk for process reliability because parts can get caught on it. In addition, unloading the skeleton is a separate work step requiring either the machine operator to move the unwieldy leftovers into a container or use loading and unloading machines. This takes time and uses too much material.

TRUMPF has introduced the Skeletonfree processing - a feature that is available on the high-end TruPunch 5000 and the new generation of TruPunch 3000 machines. This method relies fully on common split cuts. But extensive programming is no longer needed to make them because the configuration is now made by the software TruTops Punch. This enables the sheet layout to be optimised and prepares for the necessary "release strokes." The prepared parts are initially processed in sequence and then freely punched prior to discharge or removal. Parts or scrap are rotated using a separating tool with a bi-level stripper to facilitate discharge via the chute. The remaining strips are also completely crushed. The processing time per part stays the same.

Trending towards automation
"The potential of automation is still often underestimated," said Kammüller. "Many companies could greatly increase not only their competitiveness, but also counteract the impending shortage in qualified workers."